Round-flat-round surgical braids

ABSTRACT

A surgical braid comprising two non-flat sections; a tape section, the tape section being generally flat, the tape section being positioned between the two non-flat sections; and the tape section comprising a single braid, and the two non-flat sections and the tape section being formed with a continuous and gap-less braid.

REFERENCE TO COPENDING APPLICATIONS

This application is a continuation-in-part of U.S. Ser. No. 14/455,769entitled SURGICAL BRAIDS filed Aug. 8, 2014, which claims priority toU.S. Provisional Ser. No. 62/029,951 entitled SURGICAL BRAIDS ANDBRAIDING MACHINE filed Jul. 28, 2014, U.S. Provisional Ser. No.61/863,770 entitled SURGICAL BRAID filed Aug. 8, 2013, and U.S.Provisional Ser. No. 61/935,244 entitled SURGICAL BRAID HAVING COLORMARKINGS filed Feb. 3, 2014; this application also is a continuation ofPCT Application No. PCT/US15/14307 entitled SURGICAL BRAID filed Feb. 3,2015, which claims priority to U.S. Provisional Ser. No. 62/097,847entitled SURGICAL BRAID filed Dec. 30, 2014. The entire disclosures ofthe foregoing applications are hereby incorporated by reference.

BACKGROUND

Surgical braids are generally used by physicians and other medicalprofessionals to close an open wound or otherwise repair tissue, in aneffort to facilitate proper healing. Surgical braids are also used byorthopedic surgeons for a variety of purposes such as securing ligamentsand muscles to a bone. Surgical braids are typically formed by braidingtogether several strands of filaments, fibers, yarns, and the like.

During operation, the particular stitch and knot used by a surgeon canbe important to the healing process of the wound. If stitched and tiedimproperly, the surgical braid could damage tissue or not adequatelysecure the tissue. Surgical braids formed of a single color are oftendifficult for a medical professional to see and track. In particular,due to the uniform color, medical professionals have difficultyidentifying movement and position of the surgical braid.

SUMMARY

In general terms, this patent document is directed to surgical braids,and apparatuses and method for making surgical braids.

One aspect is a surgical braid comprising two non-flat sections. A tapesection is positioned between the two non-flat sections and is generallyflat. The two non-flat sections and the tape section are formed with acontinuous and gap-less braid.

Another aspect of the surgical braid comprises two non-flat sections. Atape section is positioned between the two non-flat sections and isgenerally flat. The tape section comprises a single braid, and the twonon-flat sections and the tape section are formed with a continuous andgap-less braid.

Another aspect of the surgical braid comprises a plurality of strandsbraided into two non-flat sections and a tape section, the tape sectionbeing generally flat and positioned between the two non-flat sections.The surgical braid further comprises first and second end portions, andfirst and second transition portions. The first end portion isoppositely disposed from the second end portion. Two or more of thestrands are continuously braided between the first and second endportions. The first transition portion positioned between one non-flatsection and the tape section, the second transition portion positionedbetween the other non-flat section and the tape section. The tapesection comprises first and second edge portions extending between thefirst and second transition portions, the first edge portion oppositelydisposed from the second edge portion. The plurality of strands areinterlaced into a single braid and a substantially uniform pattern asthey pass through the tape section, the single braid and substantiallyuniform pattern extends between the first and second transition portionsand between the first and second end portions forming a single flatbraid between the two non-flat sections.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side view of an example braiding machine.

FIG. 2 is a schematic top view of an example braiding assembly.

FIGS. 3A-3F illustrate examples of a braiding track plate with examplegates engaged.

FIGS. 4A and 4B illustrate an example gate.

FIGS. 5A and 5B illustrate an example operation of the gate of FIGS. 4Aand 4B.

FIG. 6 is a schematic perspective view of an example bobbin carrierassembly.

FIG. 7 is a top view of the bobbin carrier assembly of FIG. 6.

FIG. 8 is a side view of the bobbin carrier assembly of FIG. 6.

FIG. 9 is a schematic cross-sectional view of the braiding assembly ofFIG. 2, illustrating two adjacent first horn gear assemblies.

FIG. 10 is a schematic cross-sectional view of the braiding assembly ofFIG. 2, illustrating two adjacent second horn gear assemblies.

FIG. 11 is a schematic cross-sectional view of the braiding assembly ofFIG. 2, illustrating adjacent first and second horn gear assemblies.

FIG. 12 is a schematic diagram of an example cutting system.

FIGS. 13A-13D are a schematic view of an example inline cutting systemof FIG. 12, which is configured to be used with a braiding machine.

FIG. 13E is a flowchart illustrating an example method of operating thecutting system of FIGS. 13A-13D.

FIG. 14A is a schematic view of another example inline cutting system ofFIG. 12, which is configured to be used with a braiding machine.

FIG. 14B is a flowchart illustrating an example method of operating thecutting system in accordance with the example operation of FIG. 14A.

FIG. 15 is a schematic view of yet another example inline cutting systemof FIG. 12, which is configured to be used with a braiding machine.

FIG. 16 shows an example spool.

FIG. 17 is a schematic diagram of an example control system for abraiding machine and a cutting system.

FIG. 17A is a schematic diagram of the control system of FIG. 17 for abraiding machine.

FIG. 17B is a schematic diagram of the control system of FIG. 17 for acutting system.

FIG. 18 is a block diagram illustrating an example computing device.

FIG. 19 illustrates an example braid with alternating different patternsdefined by two trace strands.

FIG. 20 illustrates an example braid with alternating different patternsdefined by four trace strands.

FIG. 21 illustrates an example braid with alternating different patternsdefined by six trace strands.

FIG. 22 illustrates an example braid with alternating different patternsdefined by eight trace strands.

FIG. 23 illustrates an example configuration of the braiding machinewhen a surgical braid is made to a certain length.

FIG. 24 illustrates the positions of the bobbin carriers at step 2 whenthe horn gears rotate 90 degrees about their rotational axes,respectively, from the positions of FIG. 23.

FIG. 25 illustrates the positions of the bobbin carriers at step 3 whenthe horn gears rotate 90 degrees about their rotational axes,respectively, from the positions of FIG. 24.

FIG. 26 illustrates the positions of the bobbin carriers at step 4 whenthe horn gears rotate 90 degrees about their rotational axes,respectively, from the positions of FIG. 25.

FIG. 27 illustrates the positions of the bobbin carriers at step 5 whenthe horn gears rotate 90 degrees about their rotational axes,respectively, from the positions of FIG. 26.

FIG. 28 illustrates the positions of the bobbin carriers at step 6 whenthe active track horn gears rotate 90 degrees, while the passive trackhorn gears remain still, from the positions of FIG. 27.

FIG. 29 illustrates the positions of the bobbin carriers at step 7 whenthe horn gears rotate 90 degrees about their rotational axes,respectively, from the positions of FIG. 28.

FIG. 30 illustrates the positions of the bobbin carriers at step 8.

FIG. 31 illustrates the positions of the bobbin carriers at step 9.

FIG. 32 is a diagram illustrating example paths of the bobbin carrierassemblies.

FIG. 33 illustrates an example braid with a cross-striped pattern.

FIG. 34 illustrates an example braid with a parallel-striped pattern.

FIG. 35 illustrates an example braid with a crossing pattern.

FIG. 36 is a top plan view of a surgical braid showing some details ofthe fibers forming the surgical braid.

FIG. 37 is a side plan view showing the general shape of the surgicalbraid illustrated in FIG. 36 without the details of the fibers formingthe braid.

FIG. 38 is a cross-sectional view of the surgical braid illustrated inFIG. 36, showing the surgical braid before it passes through pinchrollers.

FIG. 39 is a cross sectional view of the surgical braid illustrated inFIG. 36, showing the surgical braid after it passes through pinchrollers.

FIG. 40 is a cross-sectional view of the surgical braid illustrated inFIG. 36

FIG. 41 illustrates the surgical braid of FIG. 36 with one or more tracestrands.

FIG. 42 illustrates the position of gates and the path of bobbin carrierassemblies when making the surgical braid illustrated in FIGS. 36-40.

FIG. 43 illustrates the position of gates and the path of bobbin carrierassemblies when making the surgical braid illustrated in FIGS. 36-40.

FIG. 44 is a diagram illustrating an example path of the bobbin carrierassemblies on the braiding track plate.

FIG. 45 is a diagram illustrating an example path of the bobbin carrierassemblies on the braiding track plate.

FIG. 46 illustrates the surgical braid of FIG. 36 with one or morebifurcated sections.

FIG. 47 illustrates an example surgical braid with a plurality of legsections.

FIG. 48 is a side view schematic diagram of a 16-filament surgical braidshowing details of the fibers forming the surgical braid.

FIG. 49A is a cross-sectional view of the surgical braid illustrated inFIG. 48.

FIG. 49B is a cross-sectional view of the surgical braid illustrated inFIG. 48.

FIG. 50 is a side view schematic diagram of a 16-filament surgical braidshowing details of the fibers forming the surgical braid.

FIG. 51A is a cross-sectional view of the surgical braid illustrated inFIG. 50.

FIG. 51B is a cross-sectional view of the surgical braid illustrated inFIG. 50.

FIG. 52 is a side view schematic diagram of a 16-filament surgical braidshowing details of the fibers forming the surgical braid.

FIG. 53A is a cross-sectional view of the surgical braid illustrated inFIG. 52 taken along line 5-5.

FIG. 53B is a cross-sectional view of the surgical braid illustrated inFIG. 52.

FIG. 53C is a cross-sectional view of the surgical braid illustrated inFIG. 52.

FIG. 54 is a side view schematic diagram of a 16-filament surgical braidshowing details of the fibers forming the surgical braid.

FIG. 55A is a cross sectional view of the surgical braid illustrated inFIG. 54.

FIG. 55B is a cross sectional view of the surgical braid illustrated inFIG. 54.

FIG. 56 is a side view schematic diagram of a 16-filament surgical braidshowing details of the fibers forming the surgical braid.

FIG. 57A is a cross sectional view of the surgical braid illustrated inFIG. 56.

FIG. 57B is a cross sectional view of the surgical braid illustrated inFIG. 56.

FIG. 58 is a side view schematic diagram of a 16-filament surgical braidshowing details of the fibers forming the surgical braid.

FIG. 59A is a cross sectional view of the surgical braid illustrated inFIG. 58.

FIG. 59B is a cross sectional view of the surgical braid illustrated inFIG. 58.

FIG. 60 is a top diagrammatic view of a 16 bobbin carrier and track.

FIG. 61 is a top diagrammatic view of a 16 bobbin carrier and track.

FIG. 62 shows a side view of a surgical braid attached to a surgicalorthopedic anchor.

FIG. 63 is a schematic top view of an example braiding assembly.

FIG. 64A is a schematic, top view of an example first horn gearassembly.

FIG. 64B is a schematic, top view of an example second horn gearassembly.

FIG. 64C is a schematic, top view of another example second horn gearassembly.

FIG. 65A illustrates an embodiment of a track plate and a track of FIG.63.

FIG. 65B illustrates an example path of bobbin carrier assemblies alongthe track of FIG. 65A.

FIG. 66A illustrates an embodiment of the track plate and the track witha gate in the closed position.

FIG. 66B illustrates an example path of bobbin carrier assemblies alongthe track of FIG. 66A.

FIG. 67 is a schematic diagram of an example braiding control system forthe braiding machine including the braiding assembly.

FIG. 68 illustrates an example braid that can be made using the braidingmachine with the braiding assembly.

FIG. 69 illustrates example positions of horn gear assemblies of thebraiding assembly, which is in a transition start position.

FIG. 70 illustrates example positions of the horn gear assemblies of thebraiding assembly, which is in an intermediate transition position.

FIG. 71 illustrates example positions of the horn gear assemblies of thebraiding assembly, which is in a transition end position.

FIG. 72 schematically illustrates an example retraction mechanism.

FIG. 73A schematically illustrates the retraction mechanism in anon-retracted position.

FIG. 73B schematically illustrates an example track with the retractionmechanism in the non-retracted position.

FIG. 73C schematically illustrates the track with the retractionmechanism in the non-retracted position.

FIGS. 74A, 74B, and 74C schematically illustrate the retractionmechanism of FIGS. 73A-73C when the retraction mechanism retracts abobbin carrier assembly from a slot of a horn gear assembly.

FIG. 75 schematically illustrates the retraction mechanism of FIG.73A-73C when the horn gear assembly rotates at a predetermined amount ofrotation.

FIG. 76A schematically illustrates the retraction mechanism of FIG.73A-73C when the retraction mechanism operates to insert the bobbincarrier assembly to the slot of the horn gear assembly.

FIG. 76B schematically illustrate the retraction mechanism of FIG. 76A.

FIG. 77 is a schematic perspective view of another example retractionmechanism 3050.

FIGS. 78A-78C schematically illustrate an example operation of theretraction mechanism 3050 of FIG. 77.

FIGS. 79A-79C illustrates an example braid that can be made using thebraiding machine with the braiding assembly.

FIG. 80A shows a cross-sectional view of a first non-flat section of thebraid illustrated in FIGS. 79A-79C.

FIG. 80B shows a cross-sectional view of a second non-flat section ofthe braid illustrated in FIGS. 79A-79C.

FIG. 80C show a cross-sectional view of a tape section 3136 of the braidillustrated in FIGS. 79A-79C.

FIG. 81 illustrates example positions of the horn gear assemblies of thebraiding assembly for braiding the flat section of the braid with atrace strand.

FIG. 82 illustrates example positions of the horn gear assemblies of thebraiding assembly for braiding the non-flat section of the braid with acore.

FIG. 83 illustrates an alternative embodiment of the braiding assemblywith a passive track.

DETAILED DESCRIPTION

Various embodiments will be described in detail with reference to thedrawings, wherein like reference numerals represent like parts andassemblies throughout the several views. Reference to variousembodiments does not limit the scope of the claims attached hereto.Additionally, any examples set forth in this specification are notintended to be limiting and merely set forth some of the many possibleembodiments for the appended claims.

For purposes of this patent document, the terms “or” and “and” shallmean “and/or” unless stated otherwise or clearly intended otherwise bythe context of their use. The term “a” shall mean “one or more” unlessstated otherwise or where the use of “one or more” is clearlyinappropriate. The terms “comprise,” “comprises,” “comprising,” “have,”“haves,” “having,” “include,” “includes,” “including,” and “such as” areinterchangeable and are not intended to be limiting. For example, theterm “including” shall be interpreted to mean “including, but notlimited to.” All ranges provided herein include the upper and lowervalues of the range unless explicitly noted. Additionally, unless statedotherwise, or clearly intended otherwise by the content of their use,shapes, configurations, structures, values and the like can varyslightly due to a variety of circumstances such as manufacturingtolerances and variables; variations in material, such as the material'sresiliency, density, stiffness, compression; and the like. Additionallyterms such as “connected” are not limited to mean that structures aredirectly linked or fastened together, but rather that they areoperationally linked together such that there can be interveningstructures.

FIG. 1 is a schematic side view of an example braiding machine 100. Inat least some embodiments, the braiding machine 100 includes a braidingassembly 102, a braiding guide mechanism 104, and a take-up mechanism106. The braiding machine 100 operates to produce a braid 108 from aplurality of strands 110 ₁-110 _(n). In some embodiments, the braidingmachine 100 can further include a pinching mechanism 112.

The braiding assembly 102 operates to feed the plurality of strands 110₁-110 _(n) through the guide assembly 104 and rotates the strands 110₁-110 _(n) to braid them together. In at least some embodiments, thebraiding assembly 102 includes horn gear assemblies, bobbin carrierassemblies, and transition mechanisms (e.g., gates). An example braidingassembly 102 is illustrated and described in more detail herein.

The braiding guide 104 defines a hole or opening through which strands110 ₁-110 _(n) pass as they move from the braiding assembly 102 to thetake-up mechanism 106. The braiding guide pulls the strands together toform the braid as the braiding assembly 102 moves the strands 110 ₁-110_(n) along a path. In at least some embodiments, the braiding guidemechanism 104 includes an iris that defines the hole through which thestrands pass and is capable of adjusting the cross-sectional area of thehole. The braiding guide mechanism 104 can have other embodiments inaddition to the embodiments described herein.

The take-up mechanism 106 is configured to wind the braid 108therearound after the braid 108 passes through the guide assembly 104.In at least some embodiments, the take-up mechanism 106 includes atake-up reel. The braid 108 wound onto the take-up mechanism 106 can bemanually delivered to post-braiding processes, such as cleaning orsterilizing the braid, cutting the braid 108 to length to formindividual braids, and other processing. In other embodiments, thetake-up mechanism 106 can be used to automatically convey the braid 108to the cutting system, as described and illustrated in more detailherein.

As described in more detail herein, the plurality of strands 110 ₁-110_(n) can include one or more trace strands that have a different colorthan the rest of the strands. The trace strands can be used to enhancevisibility of the braid 108 and help a surgeon distinguish betweendifferent sections of the braid 108. In at least some embodiments, thebraiding assembly 102 can operate to alternate between braiding thestrands 110 ₁-110 _(n) into a braid 108 having one pattern of tracestrands and braiding the strands 110 ₁-110 _(n) into a braid 108 havinga different pattern of the trace strands to produce a braid 108 having aplurality of alternating patterns of trace strands. In alternativeembodiments, the braiding assembly can operate to alternate betweenbraiding the strands 110 ₁-110 _(n) using one color scheme and braidingthe strands 110 ₁-110 _(n) using a different color scheme. Otheralternative embodiments can have a combination of varying patterns andcolor schemes.

In yet other embodiments, the braid 108 can have a plurality of tubularsections having a generally circular circumference and flat sections.For example, the braiding assembly 102 can operate to alternate betweenbraiding the strands 110 ₁-110 _(n) into a generally round, tubularbraid and braiding the strands 110 ₁-110 _(n) into a flat braid toproduce a braid having a plurality of alternating round and flatsections. The braid 108 having the round section and the flat sectionalso can include one or more colored trace strands to provide a pattern,alternating patterns, alternating colors, or combinations thereof.

In some embodiments, the braiding machine 100 can include the pinchingmechanism 112 configured to operate to compress the braid 108 totransform a round, tubular section of the braid 108 into an out-of-roundsection. For braids having a flat section, the pinch rollers also can beused to minimize any curvature along the cross-sectional area of theflat section. In at least some embodiments, the pinching mechanism 112includes opposing pinch rollers 114A and 114B. The pinching mechanism112 operates to receive the braid 108 between the pinch rollers 114A and114B after the braid 108 passes through the braiding guide mechanism114. The pinch rollers 114A and 114B compress the braid 108 such thatthe round, tubular section compresses or transforms into theout-of-round section. The pinch rollers 114A and 114B can urge theround, tubular section into a flatter profile.

The pinch rollers 114A and 114B are formed with a soft material having ahardness of about 50 durometers, although other possible embodiments canhave a hardness greater than or less than 50 durometers. A soft materialcompresses the braid 108 more gently than a hard material (e.g., metalor hard plastic) so that the pinch rollers 114A and 114B will compressthe round, tubular sections of the braid 108 into the out-of-roundsections, but not completely flatten the braid 108 or damage the strands110 ₁-110 _(n). The pinch rollers 114A and 114B can be made from avariety of materials such as a soft polymer. Additionally, a springassembly (not shown) urges the pinch rollers 114A and 114B towards oneanother to provide a force sufficient to compress the braid 108. Thespring assembly includes springs (not shown) and set screws (not shown)that pass along the center of the springs. The set screws can be rotatedto adjust the tension of the springs and the force that each of thepinch rollers 114A and 114B exerts against the braid 108. Otherembodiments of the braiding machine 100 do not include the pinchingmechanism 112.

FIG. 2 is a schematic top view of an example braiding assembly 102. Inat least some embodiments, the braiding assembly 102 includes a braidingtrack plate 120, a plurality of bobbin carrier assemblies 122A-122P, aplurality of horn gear assemblies 132A-132H and 134A-134H, and aplurality of gates 126A-126H.

As describe in more detail herein, the braiding track plate 120 definesone or more tracks 202 and 204 (as illustrated in FIGS. 3a-3f )configured to guide the plurality of bobbin carrier assemblies 122A-122Palong defined paths. The plurality of bobbin carrier assemblies122A-122P operate to carry strands 110 ₁-110 _(n) around the braidingmachine 100. The plurality of horn gear assemblies 132A-132H support anddrive the bobbin carrier assemblies along one or more active pathsdefined by the active track on the braiding track plate 120. Theplurality of horn gear assemblies 134A-134H support and drive the bobbincarrier assemblies along one or more passive paths defined by thepassive tracks on the braiding track plate 120. The gates 126A-126Hselectively guide the bobbin carrier assemblies 122A-122P from theactive track to one or more passive tracks.

In the depicted embodiment, the braiding assembly 102 includes 16 bobbincarrier assemblies 122A-122P to produce a 16-end braid 108. Otherembodiment can include any suitable number of bobbin carrier assemblies122 to make braids having any desired numbers of strands. For example,alternative braiding assemblies could have 8, 24, or 32 bobbin carrierassemblies 122, or any other suitable number of bobbin carrierassemblies 122. The braiding assembly 102 also can have different numberof horn gear assemblies 132 and 134 along the active and passive tracksand different number of gates 126 than illustrated in the exemplaryshown in FIG. 2.

In at least some embodiments, the horn gear assemblies 124 can include aset of first horn gear assemblies 132A-132H and a set of second horngear assemblies 134A-134H. In the depicted embodiment, the set of firsthorn gear assemblies 132A-132H are active track horn gear assemblies andare arranged adjacent one another around a machine axis C. The firsthorn gear assemblies 132A-132H are operated so that that the bobbincarrier assemblies 122A-122P move across adjacent first horn gearassemblies 132A-132H. The first horn gear assemblies 132A-132H areoperated in a manner that two adjacent first horn gear assemblies arerotated in opposite direction. For example, the first horn gearassemblies 132A, 132C, 132E and 132G are rotated counter-clockwise whilethe second horn gear assemblies 132B, 132D, 132F and 132H are rotatedclockwise. In other embodiments, the first horn gear assemblies can beconfigured to rotate in different manners. As described in more detailherein, the first horn gear assemblies 132 can be mechanically linkedand operated together.

The second horn gears 134A-134H are passive track horn gears and arearranged radially outside the set of the first horn gear assemblies132A-132H and are located adjacent the first horn gear assemblies132A-132H, respectively. In the depicted embodiment, the set of secondhorn gear assemblies are paired in quadrants 136A-136D. For example, thepassive horn gear assemblies 134A and 134B are paired in a firstquadrant 136A and operated to rotate in opposite directions. The passivehorn gear assemblies 134A and 134B in the first quadrant 136A arearranged adjacent active horn gear assemblies 132A and 132B,respectively, so that at least one of the bobbin carrier assemblies122A-122P can selectively move between the active horn gear assemblies132A and 132B and the passive horn gear assemblies 134A and 134B in thefirst quadrant 136A. Similarly to the first quadrant 136A, the secondhorn gear assemblies 134C and 134D are paired in a second quadrant 136Band operated to rotate in opposite direction. The passive horn gearassemblies 134C and 134D are adjacent active horn gear assemblies 132Cand 132D. Similarly, the third quadrant 136C includes second horn gearassemblies 134E and 134F, which are adjacent active horn gear assemblies132E and 132F, respectively. The fourth quadrant 136D includes secondhorn gear assemblies 134G and 134H, which are adjacent active horn gearassemblies 132G and 132H, respectively.

In at least some embodiments and as described in more detail herein, thepassive horn gears 134A-134H in quadrants 136A-136D can be mechanicallylinked with an arrangement of gears, or any other suitable structure, tobe operated together by a single motor connected to one of the secondhorn gear assemblies 134A-134H. In other embodiments, each pair ofpassive horn gears 134 in the quadrants 136A-136D can be independentlyoperated by separate motors that are connected to one of the passivehorn gears in the pair (e.g., passive horn gear 134A in quadrant 136A).In yet other embodiment, each of the passive horn gears 134A-134H areeach connected to a separate motor and can be driven independently fromeach other.

In at least some embodiments, the plurality of gates 126A-126H can bearranged between the active horn gear assemblies 132A-132H and thepassive horn gear assemblies 134A-134H, respectively. The gates126A-126H can be selectively operated to enable at least one of thebobbin carrier assemblies 122A-122P to move between the active horn gearassemblies 132A-132H and their adjacent passive horn gear assemblies134A-134H, respectively. The structure and operation of the gates126A-126H are described in more detail herein.

FIG. 3a illustrates the embodiment of the track plate 120 and active andpassive tracks as discussed with reference to FIG. 2. In thisembodiment, the track plate 120 is a plate that defines a plurality ofslots or grooves 203 that form an active track 202. The active track 202is formed to correspond to the active horn gear assemblies 132A-132H andguide the bobbin carrier assemblies 122A-122H as they are propelled bythe active horn gear assemblies 132A-132H as explained in more detailherein. The active track 202 includes eight first sub-tracks 208A-208H,which correspond to the active horn gear assemblies 132A-132H,respectively. The first sub-tracks 208A-208H are arranged abutted toeach other around the machine axis C so that the bobbin carrierassemblies 122A-122H selectively move between adjacent active sub-tracks208A-208H as they move along the active track 202. The active track 202provides a clockwise active path 207 and a counter clockwise active path209, each of which oscillates and are out-of-phase from one another.

A plurality of passive tracks 204A-204D are also formed by grooves orslots 205A-205D, respectively, defined in the braiding track plate 120.The passive track 204A is in quadrant 136A and includes passivesub-tracks 210A and 210B, which are adjacent to active sub-tracks 208Aand 208B, respectively. The passive track 204A is in quadrant 136B andincludes passive sub-tracks 210C and 210D, which are adjacent to activesub-tracks 208C and 208D, respectively. The passive track 204C is inquadrant 136C and includes passive sub-tracks 210E and 210F, which areadjacent to active sub-tracks 208E and 208F, respectively. The passivetrack 204D is in quadrant 136D and includes passive sub-tracks 210G and210H, which are adjacent to active sub-tracks 208G and 208H,respectively. The passive sub-tracks 210A-210G correspond to passivehorn gear assemblies 134A-134H, respectively, and guide the bobbincarrier assemblies 122A-122H as they are propelled by the passive horngear assemblies 134A-134H as explained in more detail herein.Additionally, the bobbin carrier assemblies 122A-122P can selectivelymove between the active track 202 and one or more of the passive tracks204A-204D as described in more detail herein.

The gates 126A-126H are positioned between active sub-tracks 208A-208Hand passive sub-tracks 210A-210H, respectively. Each gate 126A-126H hasan open position and a closed position and define grooves or slots forguiding the bobbin carrier assemblies 122A-122P either between adjacentactive and passive sub-tracks (e.g., 208A and 210A), or along the activesub-track and past the adjacent passive sub-tracks (e.g., along 208A andpast 210A).

Referring to FIGS. 4a, 4b, 5a, and 5b , each gate 126 includes a gatebody 220 that defines inter-track slots or grooves 228A and 228B thatform inter-track paths, and intra-track slots or grooves 226A and 226Bthat form intra-track paths. Each gate 126 has an open position and aclosed position.

FIGS. 5a and 5b illustrate the open and closed positions of the gate 126with respect to active sub-track 208A, passive sub-track 210A, and gate126A, although the operation described with respect to gate 126A willapply to all of the gates and the subtracks with which they are related.When in the open position as illustrated in FIG. 5b , the inter-trackgroove or path 228A has one end aligned with and open to the groove 203of active sub-track 208A and an opposite end aligned with and open tothe groove 205 of passive sub-track 210A. Similarly, the inter-trackgroove or path 228B has one end aligned with and open to the groove 203of active sub-track 208A and an opposite end of inter-track groove 228Aaligned with and open to the groove 205 of passive sub-track 210A. Theinter-track paths 228A and 228B provide a bridge to guide bobbin carrierassemblies between an active sub-track (e.g., 208A) and its adjacentpassive sub-track (e.g., 210A). In the exemplary embodiment illustratedin FIGS. 5a and 5b , the bobbin carrier assemblies 122 can travel alongthe active sub-track 208A in one direction (e.g., clockwise or counterclockwise), move to the adjacent passive sub-track 210A, and then travelalong the passive sub-track in an opposite direction (e.g.,counterclockwise or clockwise), respectively. The intra-track grooves orpaths 226A and 226B are not aligned with either the active or passivesub-tracks 208A or 210A when the gate 126A is in the open position.

When in the closed position as illustrated in FIG. 5a , the intra-trackgroove or path 226A has both ends aligned with and open to opposingsegments of the groove 203 of active sub-track 208A. The intra-trackgroove or path 226A is configured to maintain a continuous path alongthe active sub-track 208A that bypasses the adjacent passive sub-track210A, and to guide the bobbin carriers 222 to stay on the activesub-track 208A and move past the adjacent passive sub-track 210A.Similarly, the intra-track groove or path 226B has both ends alignedwith and open to opposing segments of the groove 205 of active sub-track210A. The intra-track groove or path 226B is configured to maintain acontinuous path along the passive sub-track 210A that bypasses theadjacent active sub-track 208A and to guide the bobbin carriers 222 tostay on the passive sub-track 210A and move past the adjacent activesub-track 208A. An alternative embodiment of the gates 126 might includeonly one intra-track groove or path, such as the intra track groove orpath 226A to selectively maintain bobbin carrier moving along the activesub-track 208A and past the passive sub-track 210A. The inter-trackgrooves or paths 228A and 228B are not aligned with either the active orpassive tracks when the gate 126 is in the closed position.

In the illustrated embodiment, the gates 126 can be rotatably nested inthe braiding track plate 120 such that the top surface 210 of the gatebody 220 is flush with the top surface of the braiding track plate 120.In this embodiment, at least the portion of the gates 126 nested in thebraiding track plate 120 are cylindrically shaped. The gates 126 can berotatably supported on the braiding track plate 120 in differentmanners. In some embodiments, the gates 126 can be held by the gateactuating system 164. In other embodiments, the body 220 of the gates126 can have a male projection configured to be slidably engaged with acorresponding slot, groove, shoulder, ridge, or similar structure formedin the braiding track plate 120. By defining the length or range of theslot, the range of the rotational movement of the gates 126 can belimited within the slot.

In at least some embodiments, the gates 126 are switched between theopen and closed positions by rotating them 90 degrees. In otherembodiments, the gates 126 can be movable between the open and closedpositions by rotating them with a different angle than 90°. The gates126 can rotate in one direction to alternately move between the openposition and the closed position. For example, when the gates 126 canrotate a certain degree (e.g., 90 degrees) clockwise from the openposition, the gate 126 comes to the closed position. As the gates 126further rotate with the same amount of angle (e.g., 90 degrees), theycome to the open position again. In other embodiments, the gates 126 canrotate both directions to move between the open and closed positions. Inyet other configurations are possible in alternative embodiments.

Many alternative embodiments and arrangements of the active tracks,passive tracks, and gates are possible. These alternative embodimentsenable greater flexibility for defining different paths for the bobbincarrier assemblies and enables the braider 100 to make a wider varietyof different braid structures and configurations. Referring to FIG. 3b ,for example, one or more gates can be positioned between adjacent activesub-tracks to enable bobbin carrier assemblies to switch betweentravelling in the clockwise and counter clockwise directions along theactive track. In the alternative embodiment, gate 126I is positionedbetween active sub-tracks 208A and 208G, and gate 126J is positionedbetween active sub-tracks 208D and 208E. Having two or more gatespositioned between adjacent active sub-gates enables bobbin carrierassemblies to be transported along separate closed or endless paths thattraverse the clockwise and counterclockwise paths 207 and 209 of theactive track 203. Referring to FIG. 3c , another alternative embodimentincludes gates 126I-126P between each of the active sub-tracks. FIG. 3dillustrates yet another possible embodiment in which gates 126 arepositioned between the passive sub-tracks 126Q-126T.

Additionally, alternative embodiments can position the passive tracks inthe center of the active track 202, either instead of or in addition to,passive tracks positioned outside of the active track 202 as illustratedin FIGS. 3a-3d . In FIG. 3e , for example, a center passive track 660 ispositioned in the center of the active track 202 and is adjacent one ofthe active sub-tracks (e.g., 208C). A gate 126 is then positionedbetween the center passive track 660 and the adjacent active sub-track208C. Alternative embodiments might include more than one passive trackin the center of the active track 202. Alternative embodiments also caninclude center passive tracks that have two or more passive sub-tracks.FIG. 3f illustrates another possible embodiment in which there is anactive track 202 and one or more passive tracks 204A-204D arranged onthe outside of the active track as illustrated in FIGS. 3a-3d . In thesealternative embodiments, a center passive track 661 has one or morepassive sub-tracks 662 and 663, which are positioned on the inside ofthe active track 202 as illustrated in FIG. 3e . Gate 126 are positionedbetween passive sub-track 662 and active sub-track 208C, and betweenpassive sub-track 662 and passive sub-track 663.

Many different embodiments of the braider track plate, active track,passive tracks, gates, and various sub-tracks are possible in additionto those illustrated and described herein. For example, the active andsub-tracks can be implement with any structure suitable for guiding thebobbin carrier assemblies, including structures other than a braidertrack having a network of grooves or slots. There can be any number,arrangements, and configurations of the passive tracks, which can haveany structure that guides the bobbin carrier assemblies on a path otherthan the active track and path. For example, the passive tracks can haveno sub-tracks or more than two sub-tracks. The passive tracks also caninclude paths that are not generally circular as illustrated such asoblong, arcuate, and linear paths. Additionally, the gates 126 can beany structure suitable for guiding the bobbin carrier assemblies betweenthe active track and a passive track, or any structure suitable forguiding the bobbin carrier assemblies from one direction to anotherdirection (e.g., between clockwise and counterclockwise directions).Many other embodiments may be possible as well.

Furthermore, certain designs of braids having various patterns andcolors, pattern changes, color changes, and structures such asround-flat-round structures, alternating cores, bifurcations, a centralbraid with legs, and the like are disclosed herein. Additional braidshaving various combinations of these colors, patterns, and structurescan be made using the disclosed braiding machine 100 having active andpassive tracks and gates.

FIGS. 6-8 illustrate an example bobbin carrier assembly 122. Inparticular, FIG. 6 is a schematic perspective view of an example bobbincarrier assembly 122. FIG. 7 is a top view of the bobbin carrierassembly 122 of FIG. 6. FIG. 8 is a side view of the bobbin carrierassembly 122 of FIG. 6. In at least some embodiments, the bobbin carrierassembly 122 includes a carrier shaft 170, a bobbin holder 172, acarrier foot 174, and a carrier guide 176.

The bobbin holder 172 is configured to support a bobbin 184 and feed astrand 110 from the bobbin 184. The bobbin holder 172 is supported onthe shaft 170 above the carrier foot 174. In some embodiments, thebobbin holder 172 can include a first eyelet 186, a second eyelet 187,and a third eyelet 188. The strand 110 is fed from the bobbin 184,through the first eyelet 186, and then through the second eyelet 187 ata lower portion of the bobbin holder 172. The strand 110 is then routedthrough the third eyelet 188 and runs out of the bobbin holder 172 tothe braiding guide mechanism 104. The strand 110 that is routed from thefirst eyelet 186, through the second eyelet 187, and through the thirdeyelet 188 can maintain a proper tension before braiding. In thedepicted embodiment, the bobbin 184 is vertically held by the bobbinholder 172. In other embodiments, the bobbin holder 172 can beconfigured to support the bobbin 184 horizontally or at any othersuitable angle or arrangement. In yet other embodiments, the bobbinholder 172 can have any structure suitable for holding the bobbin 184.

The carrier foot 174 is configured to engage the active and passive horngear assemblies 132A-132H and 134A-134H as disclosed in more detailherein. In at least some embodiments, the carrier foot 174 includes afirst foot plate 178 and a second foot plate 180. The first foot plate178, the second foot plate 180, and the portion of the shaft 170extending therebetween engage a horn plate of the horn gear assemblies132A-132H and 134A-134H.

The carrier guide 176 includes one or more keels 182. In the depictedexample, the carrier guide 176 includes two keels 182A and 182B. Thekeels 182 can be supported on and project downward from the bottom ofthe second foot plate 180. The keels 182A and 182B are inserted into thetrack defined in the braiding track plate 120 and the gates 126A-126Hand guide the bobbin carrier assemblies 122 along the paths defined bythe track and the orientation of the gates 126A-126H. The keels 182 arerotatable around their own axis of rotation, which is orthogonal to thesecond foot plate 182. The keels 182A and 182B smoothly guide the bobbincarrier assemblies 122 along the tracks 202 and 204 and through thegates 126A-126H while preventing the bobbin carrier assembly fromspinning around the axis of the carrier shaft 170.

FIG. 9 is a partial, schematic cross-sectional view of the braidingassembly 102 of FIG. 2 taken along line 9-9, illustrating two adjacentactive horn gear assemblies 132C-132D. The other pairs of active horngear assemblies 132A and 132B, 132E and 132F, and 132G and 132H havesimilar structures.

In at least some embodiment, each of the active horn gear assemblies 132can include a horn gear plate 142 and a suitable transmission membersuch as a gear 144. The horn gear plates 142 are configured to supportone or more of the bobbin carrier assemblies 122. The horn gear plate142 defines one or more notches 128 open to its perimeter and arrangedto receive the carrier shaft 170 while the first foot plate 178 ridesalong the top of the horn gear plate 142 and the second foot plate 180rides between the horn gear plate 142 and the braiding track plate 120.The keel 182 is positioned within the active groove 203 and slides alongthe active groove 203 as the horn gear 132 rotates and the horn plate142 propels the carrier shaft 170.

Each gear 144 is configured to engage the gear 144 of the adjacentactive horn gear assemblies 132 so that the active horn gear assembliesrotate simultaneously and at the same rate. The horn gear plate 142 andthe gear 144 are connected through a horn gear shaft 146. In someembodiments, the horn gear plate 142 and the gear 144 are arranged on orover different sides of the track plate 120. For example, the carriersupport member 142 is arranged over the upper side of the track plate120 while the gear 144 is arranged on the lower side of the track plate120. In alternative embodiments, the horn plate 142 and gear 144 arepositioned on the same side of the track plate. Other embodiments arepossible as well.

An actuating mechanism such as a servo motor 148 is connected to thedrive shaft 146 and rotates the active horn gear assembly 132A, and inturn rotates the other active horn gear assemblies 132B-132H through thechain of gears 144. An encoder 150 is also connected to the active horngear assembly to monitor the operational status and/or conditions of themotor 148 (e.g., the angular locations of the horn gear assemblies 132).Alternative embodiments can use mechanisms other than a servo motor torotate the active horn gears 132. An example of an alternative mechanismis a stepper motor.

In at least some embodiments, all of the active horn gear assemblies 132can be operated by one servo motor 148 with one encoder 150 because allof the active horn gear assemblies 132A-132H are interconnected throughthe gears 144. In some embodiments, the encoder 150 can have a quadchannel of about 2000 pulses/channel. Alternative embodiments can haveany number of motors 148 to drive the active horn gear assemblies132A-132H. For example, each active horn gear assembly 132 can be drivenby a separate motor. In this embodiment, the active horn gear assemblies132A-132H do not have the gear 144 because they are all drivenindependently. In other embodiments individual groups of adjacent activehorn gear assemblies 132A-132H are driven by separate motors. Forexample, active horn gears 132A-132D could be interconnected with oneset of gears 144 and driven by one motor 148 and active horn gears132E-132H could be interconnected with a second set of gears that arenot interconnected with the first set of gear and driven by a secondmotor. Additionally transmission mechanisms other than gears can be usedto interconnect and rotate the active horn gear assemblies 132A-132H.Belts are an example of such an alternative transmission mechanism.

FIG. 10 is a partial schematic cross-sectional view of the braidingassembly 102 of FIG. 2 taken along line 10-10, illustrating two adjacentpassive horn gear assemblies 134E and 134F in quadrant 136C. Passivehorn gear assemblies 134E and 134F are substantially similar to activehorn gear assemblies 132C and 132D illustrated in FIG. 3, and eachinclude a horn plate 152 similar to horn plate 142, horn gear shaft 156similar to horn gear shaft 146, and gear 154 similar to gear 144. Thegears 154 for passive horn hear assemblies 134E and 134F areinterconnected with each other, but are not interconnected with gears ofthe active horn gear assemblies 132A-132H or the other passive horn gearassemblies 134A-134D or 132G-134H. In this structure, the passive horngear assemblies 134A-134H operate independently of the active horn gearassemblies 132A-132H and the other passive horn gear assemblies134A-134D or 132G-134H. The passive horn gear assemblies support andpropel the bobbin carrier assemblies 122 along the groove 205 of thepassive track in a manner similar to the way the active horn gearassemblies 132 support and propel the bobbin carrier assemblies 122along the groove 203 of the active track 202.

An actuating mechanism such as a servo motor 158 is connected to thedrive shaft 156 and rotates the passive horn gear assembly 134F and inturn rotates passive horn gear assembly 134E through the interconnectionof gears 154. In this embodiment, however, the motor 158 connected tothe passive horn gear 134F does not cause passive horn gears 134A-134Dor 132G-134H to rotate. An encoder 160 also is connected to the passivehorn gear assembly 134F to monitor the operational status and/orconditions of the motor 158 and passive horn gears 134F and 134E (e.g.,the angular locations of the horn gear assemblies 134F and 134E). Insome embodiments, the encoder 160 can have a quad channel of about 2000pulses/channel. Alternative embodiment can use mechanisms other than aservo motor to rotate the passive horn gears 134F and 134E. An exampleof an alternative mechanism is a stepper motor. The structure of theother pairs of passive horn gears 134A and 134B, 134C and 134D, and 134Gand 134H are substantially similar to the pair of passive horn gears134E and 134F.

Alternative embodiments can have any number of motors 158 to drive thepassive horn gears 134A-134H. For example, all of the passive horn gearassemblies 134A-134H could be interconnected through a common chain ofgears or other transmission mechanisms such as belts and then driven bya single motor. In yet other embodiments, each passive horn gearassembly 134A-134H can be driven by a separate motor. In thisembodiment, the passive horn gear assemblies 134A-134H do not have thegear 154 because they are all driven independently.

FIG. 11 is a partial schematic cross-sectional view of the braidingassembly 102 of FIG. 2 taken along line 11-11, illustrating adjacentactive and passive horn gear assemblies 132G and 132F, respectively.Active horn gear assembly 132G is substantially similar to active horngear assembly 132C, and includes horn plate 142, gear 144, and horn gearshaft 146. Active horn gear assembly 132 is not driven directly by amotor in the illustrated embodiment. Rather the gear 144 of active horngear assembly 132C is driven by the motor 148, and the rotational motionof the motor 148 is translated to each of the gears 144 in the activehorn gear assemblies 132A-132H. Passive horn gear assembly 134G issubstantially similar to passive horn gear assembly 134E and includeshorn plate 152, gear 154, and horn gear shaft 156. Passive horn gearassembly is not driven directly by a motor in the illustratedembodiment. Rather, the gear 154 of passive horn gear assembly 134G isdriven by the motor 158 and the rotational motion of the motor 158 istranslated to the passive horn gear assembly 134G by the gears 154 inthe passive horn gear assemblies 134G and 134H.

As described herein, the active horn gear assemblies 132A-132H and thepassive horn gear assemblies 134A-134H are operated independently fromeach other. In this configuration, teeth of the gears 144 and 154 do notmesh or otherwise engage each other. In one possible embodiment, thegears 144 and 154 have the same diameter, but the centerline for thehorn gear shafts 146 and 156 are separated by a distance greater thanthe diameter. In an alternative embodiment, the gears 144 and 154 havedifferent diameters.

The gate 126 is positioned between the active and passive horn gearassemblies 132G and 134G. A gate actuating system 164 is connected tothe gate 126 and rotates the gate 126 between open and closed positions.In at least some embodiments, the gate actuating system 164 can be ahydraulic operating system. The hydraulic operating system can include ahydraulic motor. Examples of the hydraulic motor include a gear and vanemotor, a gerotor motor, an axial plunger motor, a radial piston motor,and other motors of any type suitable for actuating the gate 126. Inother embodiments, the gate actuating system 126 can include a linearactuator and linkage configured to rotate the gate 126 betweenpositions. In other embodiments, the gate actuating system 164 caninclude one or more solenoids of any type, such as electromechanicalsolenoids, rotary solenoids, rotary voice coils, pneumatic solenoidvalves, and hydraulic solenoid valves. In yet other embodiments, thegate actuating system 164 can include a pneumatic operating system. Forexample, the pneumatic operating system can include a pneumatic indexer,rack and pinion arrangement or a belt. In yet other embodiments, thegate actuating system 164 can include a motor, such as a servo orstepper motor. In this configuration, the angular location of the gate126 can be monitored through an encoder. In yet other embodiments, thegate 126 can be operated by other arrangement suitable for rotating thegate 126. In yet other embodiments, the gate 126 can be operated byeither or both of the active track motor 148 or the passive track motor158.

FIG. 12 is a schematic diagram of an example cutting system 260. In atleast some embodiments, the cutting system 260 is operated to receivethe braid 108 from the braiding machine 100 and cut it to length to formindividual braids. The braiding machine 100 and the cutting system 260can be controlled by a control system 240. The braiding machine 100includes a braider control system 242, as part of the control system240, configured to control the braiding machine 100. The cutting system260 includes a cutter control system 262, as part of the control system240, configured to control the cutting system 260. In at least someembodiments, the braider control system 242 and the cutter controlsystem 262 are connected to a control computing device 244 configured tointegrally control the braiding machine 100 and the cutting system 260.An example control system 240 is illustrated and described in moredetail with reference to FIG. 17.

FIGS. 13a-13d are schematic views of an example inline cutting system260 of FIG. 12, which is configured to be used with a braiding machine100. The inline cutting system 260 is configured to precisely cutting atransition braid 108 produced and fed from the braiding machine 100. Inat least some embodiments, the inline cutting system 260 includes a setof spools including a first spool 266 and a second spool 268, a set ofgripping devices including a first gripping device 270, a secondgripping device 272 and a third gripping device 274, a heating device276, a cutting device 278, and a tray 280.

The first and second spools 266 and 268 are configured to draw the braid108 from the braiding machine 100 and retain them for the subsequentcutting process by the cutting system 260. In at least some embodiments,one of the first and second spools 266 and 268 operates to take off thebraid 108 from the braiding machine 100, thereby being referred to as atakeoff roller or spool. In at least some embodiments, the takeoff spoolis powered by a servo motor to control the angular speed of the spool.The other spool of the first and second spools 266 and 268 is notoperated by a separate power source and configured to freely spin. Thisspool can also be referred to herein as an idler spool. As depicted, thefirst and second spools 266 and 268 are bound by the wrapped braid 108and thus the idler spool rotates at the same rate as the takeoff spool,which is operated by the servo motor. In at least some embodiments, thetakeoff spool is operated by a stepper motor.

In at least some embodiments, the braid 108 wraps around the set of thespools 266 and 268 multiple times to reduce a tension T1 on the braid108 until the braid 108 has a predetermined exit tension T2 at theoutlet of the set of the spools 266 and 268. The predetermined exittension T2 can be selected to be suitable for the cutting process by thecutting system 260. In general, the wraps of the braid 108 increasearound the spools 266 and 268, the exit tension T2 of the braid 108decreases. The spools 266 and 268 wrap the braid 108 to constantlymaintain the exit tension T2 less than the original tension T1 on thebraid 108. In at least some embodiments, the braid 108 is wrappedbetween 2 to 10 times to provide a proper exist tension. In otherembodiments, the braid 108 is wrapped 4 or 5 times. In yet otherembodiments, the braid 108 is wrapped around the spools.

The gripping devices 270, 272 and 274, along with a linear rail oractuator 267 of the cutting system 260, are used to keep tension on thebraid during heating and cutting operations. In at least someembodiments, at least one of the gripping devices 270, 272 and 274 canbe operated to move at the speed of the braid, which can be calculatedfrom the takeoff speed.

The gripping devices 270, 272 and 274 are operated by actuatingmechanisms 271, 273 and 275, respectively. In at least some embodiments,the actuating mechanisms 271, 273 and 275 can include servo motors. Theservo motors can include encoders 291, 293 and 295 configured to monitorthe operational status and/or conditions of the servo motor. In otherembodiments, the actuating mechanisms 271, 273 and 275 can includestepper motors.

The first gripping device 270 is configured to move along a conveyingline L and operates to pull the braids 108 to predetermined pointsand/or with predetermined tensions on the braid 108 as the braid 108exits from the first and second spools 266 and 268. In at least someembodiments, the first gripping device 270 operates to contact the braid108 and create pressure onto the braid 108 so that the braid 108 doesnot slip along the conveying line L. In at least some embodiments, thefirst gripping device 270 is controlled by a linear actuator driven by aservo motor. In other embodiments, the first gripping device 270 isoperated by a stepper motor. In at least some embodiments, this motor isconfigured as a slave of the motor that operates the takeoff spool asillustrated above. By taking input from the motor of the takeoff spool,the first gripping device 270 is operated at the same speed as the braid108 and, thus, the exit tension of the braid 108 can be maintainedproperly to continue a consistent braid. Further, this configurationallows controlling the position of the transition braid 108 accurately.

In at least some embodiments, the second and third gripping devices 272and 274 can be stationary while the first gripping device 270 isconfigured to be linearly movable. In other embodiments as described inmore detail herein, one of the second and third gripping devices 272 and274 can move while the first gripping device 270 is movable in order toprevent interference to the braiding machine 100 during cutting process.In yet other embodiments, both of the second and third gripping devices272 and 274 can move, either independently or as a unit, as the firstgripping device 270 is movable.

The heating device 276 is operated by a heater actuating mechanism 277.In at least some embodiments, the heater actuating mechanism 277 caninclude a hydraulic operating system. The hydraulic operating system caninclude a hydraulic motor. Examples of the hydraulic motor include agear and vane motor, a gerotor motor, an axial plunger motor, a radialpiston motor, and other motors of any type suitable for actuating thegate 126. In other embodiments, the heater actuating mechanism caninclude one or more solenoids of any type, such as electromechanicalsolenoids, rotary solenoids, rotary voice coils, pneumatic solenoidvalves, and hydraulic solenoid valves. In yet other embodiments, theheater actuating mechanism can include a pneumatic operating system. Forexample, the pneumatic operating system can include a pneumatic indexer,rack and pinion arrangement or a belt, and a stepper motor or servomotor arrangement. In yet other embodiments, the heater actuatingmechanism can include a motor, such as a servo motor. In thisconfiguration, the angular location of the motor can be monitoredthrough a motor encoder. In yet other embodiments, the motor can be astepper motor. In yet other embodiments, the heating device 276 can beoperated by other arrangement suitable for actuating the heating device276.

The cutting device 278 can be operated by a cutter actuating mechanism279. The cutter actuating mechanism 279 can be configured in a similarmanner to the actuation of the heating device 276. Thus, the descriptionfor the cutter actuating mechanism 279 is omitted for brevity purposes.

FIG. 13e is a flowchart illustrating an example method 1000 of operatingthe cutting system 260 of FIGS. 13a-13d . In the depicted embodiment,the method 1000 may include operations 1002, 1004, 1006, 1008, 1010,1012, 1014, 1016, 1018, 1020, 1022, 1024, 1026, 1028, 1030, 1032, 1034,1036, 1038, and 1040.

The method 1000 typically begins at the operation 1002 where the firstgripping device 270 is operated to grip the braid 108 at a firstlocation 281. In at least some embodiments, the first location 281A islocated between the take-up reel 106 (including the first and secondspools 266 and 268) and the second gripping device 272. In otherembodiments, the first location 281A can be defined at a differentposition.

At the operation 1004, the first gripping device 270 is advanced in aforward direction D_(F) along the conveying line L as the braidingmachine 100 operates. In at least some embodiments, the first grippingdevice 270 can be operated at the same speed as the takeoff speed of thebraid 108 (i.e., the speed at which the braid 108 is drawn at thetakeoff spool) to maintain a proper tension on the braid 108. In otherembodiments, the speed of the first gripping device 270 can be adjustedbased upon different factors.

At the operation 1006, the braiding machine 100 is stopped when thebraid 108 reaches a predetermined braid length or cut point. Thepredetermined braid length or cut point can be set and input by anoperator, or automatically calculated by the control system based uponother operational parameters input by the operator. For example, asdescribed herein, the braid length can be calculated from the takeoffspeed, which can be determined by a given pick count and a given tablespeed.

At the operation 1008, the second gripping device 272, which isstationary, can operate to grip the braid 108 at a second position 281B.At this operation, the second position 218B is located between the setof the spools 266 and 268 (i.e., the take-up reel 106) and the firstgripping device 270. In at least some embodiments, the second grippingdevice 272 is arranged between the take-up reel 106 (including the firstand second spools 266 and 268) and the heating device 276. In otherembodiments, the second gripping device 272 can be positioned betweenthe take-up reel 106 and the cutting device 278. In yet otherembodiments, the second gripping device 272 can be arranged at adifferent position.

At the operation 1010, which is optional, the first gripping device 270can be operated to advance in the forward direction D_(F) to create apredetermined tension of the braid 108. The operation can be apreliminary step at which the braid 108 is properly stretched out overthe heating device 276 by the first and second gripping device 270 and272 before the braid 108 is heated at the operation 1012.

At the operation 1012, the heating device 276 is operated to heat aportion of the braid 108 that is to be cut by the cutting device 278. Inat least some embodiments, the heating device 276 is moved around theportion of the braid 108 and operates for a predetermined period of timeat a set temperature. In at least some embodiments, the heating device276 is arranged between the first gripping device 270 and the secondgripping device 272. In at least some embodiments, the heating device276 is a non-contact heat block. Once the braid 108 is heated at the settemperature, the heating device 276 can retract.

At the operation 1016, the second gripping device 272 operates to opento release the braid 108. At the operation 1018, the first grippingdevice 270 is operated to advance in the forward direction D_(F) untilthe heated portion of the braid 108 is lined up with the cutting device278. In at least some embodiments, the cutting device 278 can bearranged between the heating device 276 and the first gripping device270. In other embodiments, the cutting device 278 can be arranged atdifferent locations.

At the operation 1020, the second gripping device 272 is operated togrip the braid 108 when the braid 108 is in a predetermined position forcutting with respect to the cutting device 278. At the operation 1022,which is optional, the first gripping device 270 is operated to advancea predetermined distance in the forward direction D_(F). This operationcan be performed to provide a predetermined tension to the braid 108 tostretch out the braid 108 between the first and second gripping devices270 and 272 before the braid 108 is cut at the operation 1026.

At the operation 1024, the third gripping device 274 is operated to gripthe braid 108 at a third location 281C. In at least some embodiments,the third location 281C is located between the cutting device 274 andthe first gripping device 270. In other embodiments, the third location281C is arranged in different positions.

At the operation 1026, the cutting device 278 is operated to cut thebraid 108 between the first and third gripping devices 270 and 274. Inat least some embodiments, the cutting device 278 operates to movearound the braid 108 and shear the braid 108. At the operation 1028, thethird gripping device 274 operates to open to release the braid 108 atthe third location 281C after the braid 108 is sheared. At the operation1030, the first gripping device 270 operates to advance in the forwarddirection D_(F) to place the sheared braid 108 over the tray 280. At theoperation 1032, the first gripping device 270 operates to release thebraid 108 to drop the braid 108 into the tray 280. At the operation1034, the first gripping device 270 returns in the rearward directionD_(R) to the first location 281A.

At the operation 1036, the first gripping device 270 operates to grip anew braid 108 at the first location 281A. Since the operation 1020, thesecond gripping device 272 can remain closed to maintain the proper exittension of the braid 108 until the first gripping device 270 moves backto the first location 281A adjacent the second gripping device 272 togrip a new portion of the braid 108.

At the operation 1038, the second gripping device 272 operates to openand release the braid 108 when the first gripping device 270 returns andgrips the braid 108 near the second gripping device 272. At theoperation 1040, the braiding machine 100 resumes its operation andcontinues the braiding process. Then, the method 1000 returns to theoperation 1004.

Although the second and third gripping devices 272 and 274 arestationary in this embodiment, either or both of the second and thirdgripping devices 272 and 274 can be configured to move. In someembodiments, the third gripping devices 274 can be linearly operated asthe first gripping device 270 moves. In this configuration, the firstgripping device 270 and the third gripping device 274 can be alternatelyoperated to grip and convey the braid 108 in the forward directionD_(F). For example, when the first gripping device 270 grips the braid108 and moves it away from the cutting device 278 in the conveyingdirection L, the third gripping device 274 can stay adjacent the cuttingdevice 278. Then, as the first gripping device 270 returns close to thecutting device 278 after dropping the braid 108 onto the tray 280, thethird gripping device 274 can be operated to grip another braid 108 andmove it from the cutting device 278 in the forward direction D_(F). Inthis case, the alternating movements of the first and third grippingdevice 270 and 274 can enable the operation of the braiding machine 100without interruption or pause during cutting process. In otherembodiments, the second gripping device 272 can be selectively operatedto move, depending on the movement and/or location of the first grippingdevice 270. The second gripping device 272 can move at a lower speedthan the first gripping device 270.

In some embodiments, the cutting system 260 does not employ either ofthe second gripping device 272 and the third gripping device 274. Inother embodiments, the cutting system 260 can only use the firstgripping device 270 to perform the same or similar operations asdescribed herein.

FIG. 14a is a schematic view of another example inline cutting system260 of FIG. 12, which is configured to be used with a braiding machine100. In this embodiment, a carrier 282 is provided to avoid pausing theoperation of the braiding machine 100 and allow the braiding machine 100to continue to operate without interruption while the cutting process ofthe cutting system 260. In at least some embodiments, the carrier 282 isconfigured to move a set of the second gripping device 272, the thirdgripping device 274, the heating device 276, and the cutting device 278,and is configured to linearly moveable along the conveying line L.

The cutting system 260 in this embodiment may be operated in the samemanner as in FIG. 13, except that the carrier 282 is operated to move ina forward direction D_(F) so that the braiding machine 100 continues tobraid without interruption. The carrier 282 moves in the forwarddirection D_(F) until the first gripping device 270 moves back in arearward direction D_(R) to grip a new section of the braid 108 afterone cycle of cutting process. When the first gripping device 270 gripsthe braid 108, the carrier 282 can move back in the rearward directionD_(R) to return to its original position. An example operation of thecutting system 260 with the carrier 282 is illustrated in more detailwith reference to FIG. 14 b.

FIG. 14b is a flowchart illustrating an example method 2000 of operatingthe cutting system 260 in accordance with the example operation of FIG.14a . In the depicted embodiment, the method 2000 may include operations2002, 2004, 2006, 2008, 2010, 2012, 2014, 2016, 2018, 2020, 2022, 2024,2026, 2028, 2030, 2032, 2034, 2036, 2038, and 2040.

The method 2000 typically begins at the operation 2002 where the firstgripping device 270 is operated to grip the braid 108. In at least someembodiments, the first gripping device 270 first grips the braid 108between the take-up reel 106 (including the first and second spools 266and 268) and the second gripping device 272. In other embodiments, thefirst gripping device 270 can grip the braid 108 at a differentposition.

At the operation 2004, the carrier 282 is advanced in a forwarddirection D_(F) along the conveying line L as the braiding machine 100operates. In at least some embodiments, the carrier 282 can be operatedat the same speed as the takeoff speed of the braid 108 (i.e., the speedat which the braid 108 is drawn at the takeoff spool) to maintain aproper tension on the braid 108. In other embodiments, the speed of thecarrier 282 can be adjusted based upon different factors.

At the operation 2006, the first gripping device 270 is operated toadvance in the forward direction D_(F) faster than the carrier 282 asthe carrier 282 continue to move in the forward direction D_(F). At theoperation 2008, the second gripping device 272, which is moving as partof the carrier 282, can operate to grip the braid 108 when the braid 108reaches a predetermined braid length or cut point. The predeterminedbraid length or cut point can be set and input by an operator, orautomatically calculated by the control system based upon otheroperational parameters input by the operator. For example, as describedherein, the braid length can be calculated from the takeoff speed, whichcan be determined by a given pick count and a given table speed.

The second gripping device 272 at the operation 2008 can grip the braid108 between the set of the spools 266 and 268 (i.e., the take-up reel106) and the first gripping device 270. In at least some embodiments,the second gripping device 272 is arranged between the take-up reel 106(including the first and second spools 266 and 268) and the heatingdevice 276. In other embodiments, the second gripping device 272 can bepositioned between the take-up reel 106 and the cutting device 278. Inyet other embodiments, the second gripping device 272 can be arranged ata different position.

At the operation 2010, which is optional, the first gripping device 270can be operated to advance in the forward direction D_(F) to create apredetermined tension of the braid 108. The operation can be apreliminary step at which the braid 108 is properly stretched out overthe heating device 276 by the first and second gripping device 270 and272 before the braid 108 is heated at the operation 2012. At theoperation 2012, the heating device 276 is operated to heat a portion ofthe braid 108 that is to be cut by the cutting device 278. In at leastsome embodiments, the heating device 276 is moved around the portion ofthe braid 108 and operates for a predetermined period of time at a settemperature. In at least some embodiments, the heating device 276 isarranged between the first gripping device 270 and the second grippingdevice 272. In at least some embodiments, the heating device 276 is anon-contact heat block. Once the braid 108 is heated at the settemperature, the heating device 276 can retract.

At the operation 2016, the second gripping device 272 operates to opento release the braid 108. At the operation 2018, the first grippingdevice 270 is operated to advance faster than the carrier 282 in theforward direction D_(F) until the heated portion of the braid 108 islined up with the cutting device 278. In at least some embodiments, thecutting device 278 can be arranged between the heating device 276 andthe first gripping device 270. In other embodiments, the cutting device278 can be arranged at different locations.

At the operation 2020, the second gripping device 272 is operated togrip the braid 108 when the braid 108 is in a predetermined position forcutting with respect to the cutting device 278. At the operation 2022,which is optional, the first gripping device 270 is operated to advancefaster than the carrier 282 a predetermined distance in the forwarddirection D_(F). This operation can be performed to provide apredetermined tension to the braid 108 to stretch out the braid 108between the first and second gripping devices 270 and 272 before thebraid 108 is cut at the operation 2026.

At the operation 2024, the third gripping device 274 is operated to gripthe braid 108. In at least some embodiments, the third gripping device274 grips the braid 108 between the cutting device 274 and the firstgripping device 270. In other embodiments, the third gripping device 274is arranged to grip the braid 108 in different positions.

At the operation 2026, the cutting device 278 is operated to cut thebraid 108 between the first and third gripping devices 270 and 274. Inat least some embodiments, the cutting device 278 operates to movearound the braid 108 and shear the braid 108. At the operation 2028, thethird gripping device 274 operates to open to release the braid 108 atthe third location 281C after the braid 108 is sheared. At the operation2030, the first gripping device 270 operates to advance faster than thecarrier 282 in the forward direction D_(F) to place the sheared braid108 over the tray 280. At the operation 2032, the first gripping device270 operates to release the braid 108 to drop the braid 108 into thetray 280. At the operation 2034, the first gripping device 270 returnsin the rearward direction D_(R) to the first location 281A.

At the operation 2036, the first gripping device 270 operates to grip anew braid 108. In at least some embodiments, the first gripping device270 can grip the braid 108 between the take-up reel 106 and the secondgripping device 272. In other embodiments, the first gripping device 270can grip the braid 108 at a different position.

Since the operation 2020, the second gripping device 272 can remainclosed to maintain the proper exit tension of the braid 108 until thefirst gripping device 270 moves back to the first location 281A adjacentthe second gripping device 272 to grip a new portion of the braid 108.At the operation 2038, the second gripping device 272 operates to openand release the braid 108 when the first gripping device 270 returns andgrips the braid 108 near the second gripping device 272. At theoperation 2040, the carrier 282 returns to its original location. Then,the method 2000 returns to the operation 2004.

FIG. 15 is a schematic view of yet another example inline cutting system260 of FIG. 12, which is configured to be used with a braiding machine100. In this embodiment, the cutting system 260 is configured as acircular track 283 to continuously perform cutting process whileallowing the braiding machine 100 to continue to operate without pause.

The braid 108 can be fed from the braiding machine 100 to the circulartrack 283 to route therearound. The cutting system 260 can include oneor more gripping devices 284. In the depicted embodiment, the cuttingsystem 260 includes three gripping devices 284A, 284B and 284C. Thegripping devices 284 can independently move along the circular track 283in a conveying direction L2.

In at least some embodiments, the heating device 276 and the cuttingdevice 278 is movably arranged out of the circular track 283. Forexample, the heating device 276 and/or the cutting device 278 can beextended to the circular track 283 when the braid 108 is arranged inposition on the circular track 283 for heating and/or shearing. In otherembodiments, the heating and/or cutting devices 276 and 278 can beoperated in different manners.

The principle of the operation of the cutting system 260 in thisembodiment is similar to the cutting system illustrated in FIG. 13,except that the three gripping devices 284A-284C alternately changetheir roles as the first, second and third gripping devices 270, 272 and274 as illustrated in FIG. 13. For example, once the gripping devices284C, 284A and 284B operate as the first, second and third grippingdevices 270, 272 and 274, respectively, to complete one cycle of thecutting process, the gripping device 284C moves around the circulartrack 283 and functions as the second griping device 272. In this case,the gripping device 284B becomes to work as the first gripping device270 and the griping device 284A operates as the third gripping device272 to perform the next cycle of the cutting process. In otherembodiments, other configurations are possible.

FIG. 16 shows an example spool 266 or 268. In at least some embodiments,the spools 266 and 268 have a plurality of grooves 464. The grooves 464are configured to organize the braid 108 wrapped therearound. In atleast some embodiments, the grooves 464 are shapes in a “V”configuration.

One of the spools 266 and 268 are driven by a spool actuating mechanism286. In at least some embodiments, the spool actuating mechanism 286 caninclude a servo motor 287. The operational status and/or conditions ofthe servo motor 287 can be monitored a spool motor encoder 288 attachedto the spool motor 287. The status and/or conditions (e.g., the angularlocation of the motor 286 or the takeoff spool) obtained by the spoolmotor encoder 288 is fed back to the cutter control system 262 and usedto control the cutting system 260. In other embodiments, the spool motor286 is a stepper motor. In yet other embodiments, the spool actuatingmechanism 286 can be configured in different manners.

The spool motor 286 can be controlled independently from the activetrack and passive track motors 148 and 158 in order to allow changingthe pick count of the braid. In at least some embodiments, the pickcounts and the horn gear rotations (i.e., table speeds) can be used tocalculate the length of the braid, which can be used in the cuttingsystem 260.

FIG. 17 is a schematic diagram of an example control system 240 for thebraiding machine 100 (FIG. 17A) and the cutting system 260 (FIG. 17B).In at least some embodiments, the control system 240 includes a braidercontroller 242, one or more braider sensors 243, servo drives 245, acontrol computing device 244, a program 248, a user interface 250, acutter controller 262, one or more cutter sensors 294, and servo drives296.

The braider controller 242 is configured to control at least some of thecomponents of the braiding system 100. Examples of the braidercontroller 242 include a programmable logic controller (PLC) and acomputer numerical control (CNC). Although the depicted embodiment ofthe braider controller 242 is primarily illustrated as a PLC, thebraider controller 242 can be of any type suitable for controlling thebraiding machine 100 as desired.

The braider controller 242 is connected to the servo drives 245 andcommunicates with the servo drives 245 to control the servo motors 148,158 and 278.

The braider sensors 243 operate to monitor the status, position, and/oroperation of the components of the braiding machine 100. For example,the sensors 243 can be used to detect the relative positions of thebobbin carrier assemblies 122, the horn gear assemblies 124, and/or thegates 126. Examples of the sensors 243 include proximity sensors andcameras.

The servo drives 245 are configured to operate the motors 148, 158 and278 based upon signals from the braider controller 242. For example, theservo drives 245 can operate to receive a command signal from thebraider controller 242, amplify the signal, and transmit electriccurrent to the servo motors 148, 158 and 278 in order to produce motionof the motors proportional to the command signal. Other configurationsare also possible. The encoders 150, 160 and 288 attached to the motors148, 158 and 278 operates to report the motors' actual status back tothe servo drives 245 and/or the braider controller 242. Then, the servodrives 245 can compare the actual motor status with the command motorstatus and alter the voltage frequency or pulse with to the motors so asto correct for any deviation from the commanded status.

The control computing device 244 operates to manage both of the braidercontroller 242 and the cutter controller 262. An example of the controlcomputing device 244 is illustrated and described in more detail withreference to FIG. 18.

The program 248 is executed in the control computing device 244 tocontrol the braider controller 242 and the cutter controller 262. Theprogram 248 contains a variety of algorithms for different operations ofthe braiding machine 100 and the cutting system 260. In at least someembodiments, the control computing device 244 can be provided withdifferent programs 248 for different types of braid 108, such asdifferent patterns of one or more trace strands and/or alternatingflat/round sections, as described herein. The programs 248 are composedbased upon a plurality of operational parameters, which are describedherein.

The user interface 250 provides an interface for an operator to interactwith to input user instructions and commands to the control computingdevice 244, and to monitor the status of the braiding machine 100 andthe cutting system 260.

The cutter controller 262 is configured to control at least some of thecomponents of the cutting system 260. Examples of the braider controller262 include a programmable logic controller (PLC) and a computernumerical control (CNC). Although the depicted embodiment of the cuttercontroller 262 is primarily illustrated as a PLC, the cutter controller262 can be of any type suitable for controlling the braiding machine 100as desired.

The cutter sensors 294 operate to monitor the status, position, and/oroperation of the components of the cutting system 260. For example, thecutter sensors 294 can be used to detect the relative positions of thegripping devices 270, 272 and 274, the heating device 274, and/or thecutting device 276. Examples of the sensors 243 include proximitysensors and cameras.

The servo drives 296 (including 296A-296C) are configured to operate themotors 271, 273 and 275 upon signals from the cutter controller 262. Forexample, the servo drives 296 can operate to receive a command signalfrom the cutter controller 262, amplify the signal, and transmitelectric current to the servo motors 271, 273 and 275 in order toproduce motion of the motors proportional to the command signal. Otherconfigurations are also possible. The encoders 291, 293 and 295 attachedto the motors 271, 273 and 275 operates to report the motors' actualstatus back to the servo drives 296 and/or the cutter controller 262.Then, the servo drives 296 can compare the actual motor status with thecommand motor status and alter the voltage frequency or pulse with tothe motors so as to correct for any deviation from the commanded status.

In at least some embodiments, the braiding machine 100 and the cuttingsystem 260 can be controlled depending on a plurality of operationalparameters. An operator of the system can interact with the userinterface 250 to input one or more of the operational parameters.Examples of the operational parameters include transition points ofpattern, pick counts, take-off speeds, table speeds (i.e., the rotationspeeds of the horn gear assemblies or the motors thereof), braidlengths, cut locations, temperatures of the heating device 276, aheating time, and the total number of parts per lot. The braidtransition points indicate points of the braid 108 at which the patternsof the braid 108 and/or the braiding types of the braid 108 change. Thepick counts indicate the number of crossovers of alternate endings in agiven length of the braid 108. The pick counts can change as thepatterns and/or types vary. The take-off speeds is a speed of the braid108 that takes off from the braiding machine 100. For example, thetake-off speeds can be calculated from the operation of one or both ofthe first and second spools 266 and 268 (i.e., the take-up reel 106). Inat least some embodiments, the braid lengths are used to determine thecut locations of the braid 108 to produce desired lengths of individualbraids. The cut locations can be used to determine the locations of thecutting device 260.

The pick counts, the take-off speeds, the table speeds, and the braidlengths are all related. For example, the take-off speeds can becalculated from the pick counts and the table speeds. Also, the braidlengths can be calculated from the take-off speeds. In at least someembodiments, therefore, the operator can input the pick counts and thetable speeds into the control computing device 244 via the userinterface 250 to adjust the take-off speeds (and thus the braidlengths).

The cutter controller 262 is also operated based upon the operationalparameters input to the control computing device 244. In at least someembodiments, based upon these parameters, the cutter controller 262 cancontrol the linear rail speeds, the movements and/or positions of thegripping devices, the cut locations, the temperatures of the heatingdevice 276, the number of heating processes, and/or the number ofcutting cycles.

In at least some embodiments, the braider controller 242 and the cuttercontroller 292 can be separately controlled by a single controlcomputing device or multiple control computing devices.

FIG. 18 is a block diagram illustrating an example computing device 244.In some embodiments, the database system 100 and/or a device with theoperating system 110 are implemented as one or more computing deviceslike the computing device 244. It should be appreciated that in otherembodiments, the database system 100 and/or a device with the operatingsystem 110 are implemented using computing devices having hardwarecomponents other than those illustrated in the example of FIG. 18.

The term computer readable media as used herein may include computerstorage media and communication media. As used in this document, acomputer storage medium is a device or article of manufacture thatstores data and/or computer-executable instructions. Computer storagemedia may include volatile and nonvolatile, removable and non-removabledevices or articles of manufacture implemented in any method ortechnology for storage of information, such as computer readableinstructions, data structures, program modules, or other data. By way ofexample, and not limitation, computer storage media may include dynamicrandom access memory (DRAM), double data rate synchronous dynamic randomaccess memory (DDR SDRAM), reduced latency DRAM, DDR2 SDRAM, DDR3 SDRAM,solid state memory, read-only memory (ROM), electrically-erasableprogrammable ROM, optical discs (e.g., CD-ROMs, DVDs, etc.), magneticdisks (e.g., hard disks, floppy disks, etc.), magnetic tapes, and othertypes of devices and/or articles of manufacture that store data.Accordingly, in the embodiments contemplated herein, computer storagemedia includes at least some tangible medium or device. In certainembodiments, computer storage media includes non-transitory media and/ordevices. Communication media may be embodied by computer readableinstructions, data structures, program modules, or other data in amodulated data signal, such as a carrier wave or other transportmechanism, and includes any information delivery media. The term“modulated data signal” may describe a signal that has one or morecharacteristics set or changed in such a manner as to encode informationin the signal. By way of example, and not limitation, communicationmedia may include wired media such as a wired network or direct-wiredconnection, and wireless media such as acoustic, radio frequency (RF),infrared, and other wireless media.

In the example of FIG. 18, the computing device 244 includes a memory251, a processing system 252, a secondary storage device 253, a networkinterface card 254, a video interface 255, a display unit 256, anexternal component interface 257, and a communication medium 263. Thememory 251 includes one or more computer storage media capable ofstoring data and/or instructions. In different embodiments, the memory251 is implemented in different ways. For example, the memory 251 can beimplemented using various types of computer storage media.

The processing system 252 includes one or more processing units. Aprocessing unit is a physical device or article of manufacturecomprising one or more integrated circuits that selectively executesoftware instructions. In various embodiments, the processing system 252is implemented in various ways. For example, the processing system 252can be implemented as one or more processing cores. In another example,the processing system 252 can include one or more separatemicroprocessors. In yet another example embodiment, the processingsystem 252 can include an application-specific integrated circuit (ASIC)that provides specific functionality. In yet another example, theprocessing system 252 provides specific functionality by using an ASICand by executing computer-executable instructions.

The secondary storage device 253 includes one or more computer storagemedia. The secondary storage device 253 stores data and softwareinstructions not directly accessible by the processing system 252. Inother words, the processing system 252 performs an I/O operation toretrieve data and/or software instructions from the secondary storagedevice 253. In various embodiments, the secondary storage device 253includes various types of computer storage media. For example, thesecondary storage device 253 can include one or more magnetic disks,magnetic tape drives, optical discs, solid state memory devices, and/orother types of computer storage media.

The network interface card 254 enables the computing device 244 to senddata to and receive data from a communication network. In differentembodiments, the network interface card 254 is implemented in differentways. For example, the network interface card 254 can be implemented asan Ethernet interface, a token-ring network interface, a fiber opticnetwork interface, a wireless network interface (e.g., WiFi, WiMax,etc.), or another type of network interface.

The video interface 255 enables the computing device 244 to output videoinformation to the display unit 256. The display unit 256 can be varioustypes of devices for displaying video information, such as a cathode-raytube display, an LCD display panel, a plasma screen display panel, atouch-sensitive display panel, an LED screen, or a projector. The videointerface 255 can communicate with the display unit 256 in various ways,such as via a Universal Serial Bus (USB) connector, a VGA connector, adigital visual interface (DVI) connector, an S-Video connector, aHigh-Definition Multimedia Interface (HDMI) interface, or a DisplayPortconnector.

The external component interface 257 enables the computing device 244 tocommunicate with external devices. For example, the external componentinterface 257 can be a USB interface, a FireWire interface, a serialport interface, a parallel port interface, a PS/2 interface, and/oranother type of interface that enables the computing device 244 tocommunicate with external devices. In various embodiments, the externalcomponent interface 257 enables the computing device 244 to communicatewith various external components, such as external storage devices,input devices, speakers, modems, media player docks, other computingdevices, scanners, digital cameras, and fingerprint readers.

The communications medium 263 facilitates communication among thehardware components of the computing device 244. In the example of FIG.18, the communications medium 263 facilitates communication among thememory 251, the processing system 252, the secondary storage device 253,the network interface card 254, the video interface 255, and theexternal component interface 257. The communications medium 263 can beimplemented in various ways. For example, the communications medium 263can include a PCI bus, a PCI Express bus, an accelerated graphics port(AGP) bus, a serial Advanced Technology Attachment (ATA) interconnect, aparallel ATA interconnect, a Fiber Channel interconnect, a USB bus, aSmall Computing system Interface (SCSI) interface, or another type ofcommunications medium.

The memory 251 stores various types of data and/or softwareinstructions. For instance, in the example of FIG. 18, the memory 251stores a Basic Input/Output System (BIOS) 258 and an operating system259. The BIOS 258 includes a set of computer-executable instructionsthat, when executed by the processing system 252, cause the computingdevice 244 to boot up. The operating system 259 includes a set ofcomputer-executable instructions that, when executed by the processingsystem 252, cause the computing device 244 to provide an operatingsystem that coordinates the activities and sharing of resources of thecomputing device 244. Furthermore, the memory 251 stores applicationsoftware 265 including the program 248. The application software 265includes computer-executable instructions, that when executed by theprocessing system 252, cause the computing device 244 to provide one ormore applications. The memory 251 also stores program data 261. Theprogram data 261 is data used by programs that execute on the computingdevice 244.

Referring to FIG. 19-22, the braiding machine described herein can beused to make a variety of different surgical braid that have differentpatterns and structures. The braids illustrated herein are braided usinga 1-over-1 configurations, although alternative embodiment can use braidconfigurations other than a 1-over-1 braid. Additionally, the braidingmachine can be used to make braids having different structures such as agenerally tubular structure in which strands 110 follow a generallyspiral path for a full 360 degrees, a braid having a flat section,braids having bifurcations, and other braid structures. The braidingmachine 102 also can be controlled to make braids can be made with orwithout a core, spine, or reinforcing member running along the length ofthe braid. Various embodiments of the braiding machine 100 disclosedherein can make surgical braids having these structures and surgicalbraids having combinations of these structures.

The braiding machine 100 also can be used to make surgical braids formedwith a continuous braid along the entire length of the braid withoutrequiring weaving, splicing, or gluing. For example, the surgical braidcan have a continuous braid through transitions between differentstructures such as the transition from a tubular braid to a flat or tapebraid, or through a change in strands used to form a core. Somealternative embodiment might still use fastening techniques such asgluing, weaving, or splicing to form certain aspects of the surgicalbraids.

Additionally, braids can be made using trace strands 402 that differentcolors than the rest of the strands 110 used in the braid 108 to furtherenhance visibility of the surgical braid 300. For example, the braid 108can include a plurality of white strands 110 and one or more coloredtrace strands 402 that visually stands out from the rest of the strands110. When trace strands are used, braids can be made having changingcolors and changing patterns for the trace stands. Example colors thatcan be used for the strands 402 include blue, green, violet, brown,purple, black, white, or any other suitable color.

The braids 108 can be used as surgical braids. Example materials thatcan be used for strands 110 in the surgical braid include polypropylene,polyethylene, polyethylene terephthalate (PET), silk, nylon,thermoplastic fluoropolymers such as polyvinylidene fluoride,polyvinylidene difluoride (PVDF), or any combination thereof. Advantagesof such materials include added tensile strength, which reducesstretching when pulled and an axial load is applied to the braid. In atleast some possible embodiments, the surgical braid is braided with 16strands in a 1-over-1 configuration. Other embodiments are possible. Forexample, the surgical braid can be braided with more or less than 16strands, and configurations other than a 1-over-1 configuration.Additionally, the surgical braid can include strands formed withultra-high-molecular weight polyethylene (UHMWPE). In some possibleembodiment, less than about 90% of the strands in the surgical braid areUHMWPE. In other possible embodiments, less than about 75% of thestrands 306 in the surgical braid are UHMWPE. The strands can have arange of linear mass densities. For example, in at least someembodiments, the strands have a linear mass density greater than 110deniers. Other embodiments can have strands with a linear mass densityabout 110 deniers or lower. Yet other embodiments have an average ofabout 100 deniers. Alternative embodiments also can includemultifilament fibers, monofilament fibers, yarns, strands formed withbraided or twisted fibers, individual fibers, or a combination thereof.In at least some possible embodiments, the trace strand is formed usinga stronger material than the material used for the other strands of thesurgical braid. Additionally, although surgical braids are disclosed,the braiding machine 102 and methods disclosed herein can be used tomake other types of braids such as ropes, wires, and cables, and can usestrands made from any type of suitable material including metals,plant-based fibers, and chemical-based fibers.

FIGS. 19-22 illustrate braids having changing patterns of color traces,which can be made using a braiding machine having active and passivetracks as disclosed and taught herein. FIG. 19 illustrates an exemplarybraid having two trace strands 402. As illustrated, the braid 108 issubstantially tubular and has first and second sections 404 and 406 suchthat the trace strands have one pattern in the first section and adifferent pattern in the second section 406. In the illustratedembodiment, the braid 108 has a striped pattern in the first section 404and a cross pattern in the second section 406. FIG. 20 illustrates anexample braid 108 with alternating different patterns defined by fourtrace strands 402. In the depicted embodiment, the braid 108 can includea cross pattern in the section 404 and a striped pattern in the section406. FIG. 21 illustrates an example braid 108 with alternating differentpatterns defined by six trace strands 402. In the depicted embodiment,the braid 108 can include a striped pattern in the section 404 and across pattern in the section 406. FIG. 22 illustrates an example braid108 with alternating different patterns defined by eight trace strands402. In the depicted embodiment, the braid 108 can include a crosspattern in the section 404 and a striped pattern in the section 406.

In different embodiments, the trace strands in the embodimentsillustrated in FIGS. 19-22 can each have the same color, each have adifferent color, or can have different combinations of two or morecolors such that one group of trace fibers have one color and othergroup(s) of trace fibers have a different color(s). Additionally, thebraid can be formed with different patters than the stripped andcrossing patterns as illustrated. Yet other embodiment might have morethan two sections such that the patters alternate along the length ofthe fiber or such that each section has a different pattern.

When making braids having a changing patter as illustrated in FIGS.19-22, the bobbin carrier assemblies travel along clockwise andcounterclockwise paths 207 and 209 of the active track 202 during whichthe trace strands are braided into a first pattern. To transition thetraces to a second pattern, the bobbin carrier assemblies 222 are movedalong a combination of the active and passive tracks 202 and 204A-204Das illustrated in FIGS. 23-31. For purposes of illustration, the stepsand bobbin carrier positions in FIGS. 23-31 are shown using thearrangement of active and passive tracks, active and passive horn gears,and gates illustrated in FIGS. 2 and 3 a, although the steps oroperations described herein can be implemented with alternativearrangements of the active and passive tracks, active and passive horngears, and gates.

As illustrated in FIGS. 23-31, the horn gears 132A-132H and 134A-134Hoperate to carry the bobbin carriers 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B, 5A,5B, 6A, 6B, 7A, 7B, 8A, and 8B, which roughly correspond to bobbincarriers 122A-122P. As described below, the horn gears also operate toselectively transfer at least one of the bobbin carriers betweenadjacent horn gears as the horn gears rotate. In at least someembodiments, shifts of the bobbin carriers between adjacent active horngears occur at transition positions GA1-GA8. Shifts of the bobbincarriers between active horn gears and adjacent passive horn gears occurat transition points GP1-GP4 to forms continuous paths (such as paths312, 314, 316 and 318 as illustrated in FIG. 33). The bobbins can beselectively shifted between the active and passive tracks 202 and 204through gates GPA1-GPA8, which correspond to gates 126A-126H in FIGS. 2and 3 a. The transition mechanisms GPA1-GPA8 are configured toselectively guide the bobbin carriers 122 between the active and passivetracks 202 and 204A-204D. In at least some embodiments, at least one ofthe transition mechanisms GPA1-GPA8 are implemented with the gates 126.

When making the braid having two trace strands as illustrated in FIG.19, the bobbin carrier assemblies 1A and 2B are loaded with tracestrands and the remaining bobbin carriers are loaded with white stands.When making the braid having four trace strands as illustrated in FIG.20, the bobbin carrier assemblies 1A, 2A, 5A, and 6A are loaded withtrace strands and the remaining bobbin carriers are loaded with whitestands. When making the braid having six trace strands as illustrated inFIG. 21, the bobbin carrier assemblies 1A, 2B, 5A, 6B, 7A, and 4B areloaded with trace strands and the remaining bobbin carriers are loadedwith white stands. When making the braid having eight trace strands asillustrated in FIG. 22, the bobbin carrier assemblies 1A, 2A, 5A, 6A,7A, 8A, 3A, and 4A are loaded with trace strands and the remainingbobbin carriers are loaded with white stands.

In FIG. 23 illustrates a starting position (Step 1) of the bobbincarriers 222, all of the bobbin carriers 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B,5A, 5B, 6A, 6B, 7A, 7B, 8A, and 8B are located on the active track 202.To move the bobbin carrier assemblies to the next position (Step 2 inFIG. 24), the transition mechanisms GPA2, GPA4, GPA6, and GPA8, whichare collectively referred to as Gate Set A, are opened to transferselect bobbin carriers from the active track 202 to the passive track204. Then, the braiding machine 100 operates to rotate all of the horngears 132A-132H and 134A-134H about 90 degrees to transfer the bobbincarriers 2B, 4B, 6B and 8B from the active track horn gears 132B, 132H,132F and 132D to the passive track horn gears 134B, 134H, 134F and 134D,respectively. The bobbin carriers 1B, 3B, 5B and 7B remain on the activetrack 202. Further, the bobbin carriers 1A, 2A, 3A, 4A, 5A, 6A, 7A and8A remains on the active track 202 and are transferred counter-clockwisebetween adjacent active track horn gears 132A-132H.

To move the bobbin carrier assemblies from the positions illustrated inFIG. 24 to the positions illustrated in FIG. 25 (Step 3), the transitionmechanisms GPA1, GPA3, GPA5 and GPA7, which are collectively referred toas Gate Set B, are opened to transfer select associated bobbin carriersfrom the active track 202 to the passive track 204. Then the braidingmachine operates to rotate the horn gears 132A-132H and 134A-134H about90 degrees to transfer the bobbin carriers 2A, 4A, 6A and 8A from theactive track horn gears 132A, 132C, 132E and 132G to the passive trackhorn gears 134A, 134C, 134E and 134G, respectively, at the transitionpositions GA1, GA3, GA5 and GA7, respectively. The bobbin carriers 2B,4B, 6B and 8B remain on the passive track 204. Further, the bobbincarriers 1A, 2A, 3A, 4A, 5A, 6A, 7A and 8A remain on the active track202. However, the active track bobbin carriers 1B, 3B, 5B and 7B aretransferred counter-clockwise between adjacent active track horn gears132A-132H. In particular, the bobbin gear 1B is shifted from the horngear 132C to the horn gear 132D, the bobbin gear 3B is shifted from thehorn gear 132A to the horn gear 132B, the bobbin gear 5B is shifted fromthe horn gear 132G to the horn gear 132H, and the horn gear 7B isshifted from the horn gear 132E to the horn gear 132F.

To move the bobbin carrier assemblies from the positions illustrated inFIG. 25 to the positions illustrated in FIG. 26 (Step 4), all of thetransition mechanisms are closed after the bobbin carriers are movedinto their positions illustrated in FIG. 25. The braiding machine 100then operates to rotate all of the horn gears about 90 degrees. Becauseall of the transition mechanisms are closed, no bobbin carriers aretransferred between adjacent horn gears. The eight bobbin carriers 2A,2B, 4A, 4B, 6A, 6B, 8A and 8B stay on the passive track 204, and theother eight bobbin carriers 1A, 1B, 3A, 3B, 5A, 5B, 7A and 7B stay onthe active track 202. As the horn gears rotate during step 4, some ofthe bobbin carriers move across adjacent horn gear assemblies on theactive track through the transition positions GA2, GA4, GA6 and GA8.Further, some of the bobbin carriers move across the passive tracktransition positions GP1, GP2, GP3 and GP4.

To move the bobbin carrier assemblies from the positions illustrated inFIG. 26 to the positions illustrated in FIG. 27 (Step 5), the horn gearsrotate an additional 90 degrees about their rotational axes,respectively. The bobbin carriers 1B, 3B, 5B and 7B are transferredbetween adjacent horn gears on the active track 202, and the bobbincarriers 2B, 4B, 6B and 8B are transferred between adjacent horn gearson the passive track 204. In particular, the bobbin carrier 1B isshifted from the horn gear 132D to the horn gear 132E, the bobbincarrier 3B is shifted from the horn gear 132B to the horn gear 132B, thebobbin carrier 5B is shifted from the horn gear 132H to the horn gear132A, and the bobbin carrier 7B is shifted from the horn gear 132F tothe horn gear 132G. The bobbin carrier 2B is shifted from the horn gear134B to the horn gear 134A, the bobbin carrier 4B is shifted from thehorn gear 134H to the horn gear 134G, the bobbin carrier 6B is shiftedfrom the horn gear 134F to the horn gear 134E, and the bobbin carrier 8Bis shifted from the horn gear 134D to the horn gear 134C.

To move the bobbin carrier assemblies from the positions illustrated inFIG. 27 to the positions illustrated in FIG. 28 (Step 6), the activetrack horn gears 132A-132H are rotated 90 degrees while the passivetrack horn gears 134A-134H do not rotate and remain still. Accordingly,the bobbin carrier assemblies 2A, 2B, 4A, 4B, 6A, 6B, 8A, and 8B remainin the same position along the passive tracks.

To move the bobbin carrier assemblies from the positions illustrated inFIG. 28 to the positions illustrated in FIG. 29 (Step 7), the braidingmachine 100 operates to rotate all of the horn gears 132A-132H and134A-134H about 90 degree until the step 7 as shown in FIG. 29.

To move the bobbin carrier assemblies from the positions illustrated inFIG. 28 to the positions illustrated in FIG. 29 (Step 7), the transitionmechanisms GPA1, GPA3, GPA5, and GPA7 (Gate Set B) are then opened sothat bobbin carriers 2B, 4B, 6B and 8B on the passive track 204 can betransferred to the active track 202. The horn gears 132A-132H and134A-134H are then rotated about 90 degrees. The bobbin carriers 2B, 4B,6B and 8B are transferred from the passive track 204 to the active track202. The bobbin carriers 2B, 4B, 6B and 8B return to the active track204 for the first time since the step 1, but enter the slots of theactive track horn gears in which the bobbin carriers 2A, 4A, 6A and 8Ahad been placed before they were transferred from the active track 202to the passive tracks 204 in the step 3. In particular, the bobbincarrier 2B moves from the horn gear 134A to the horn gear 132A, thebobbin carrier 4B moves from the horn gear 134G to the horn gear 132G,the bobbin carrier 6B moves from the horn gear 134E to the horn gear132E, and the bobbin carrier 8B moves from the horn gear 134C to thehorn gear 132C.

To move the bobbin carrier assemblies from the positions illustrated inFIG. 29 to the positions illustrated in FIG. 30 (Step 8), all of thehorn gears are rotated about 20 degrees about their rotational axes toclear all transition mechanism locations (Step 8A). After the horn gearsare rotated 20 degrees, the transition mechanisms GPA1, GPA3, GPA5 andGPA7 (Gate Set B) are closed and then all of the horn gears are rotatedabout 90 degrees in the reverse direction (Step 8B).

To move the bobbin carrier assemblies from the positions illustrated inFIG. 30 to the positions illustrated in FIG. 31 (Step 9), the transitionmechanisms GPA2, GPA4, GPA6 and GPA8 (Gate Set A) are opened and theactive track horn gears 132A-132H are rotated about 60 degrees in thereverse direction while the passive track horn gears 134A-134H do notrotate and remain stationary (Step 9A). Then the passive track horngears 134A-134H rotate about 120 degrees in the original direction (Step9B). The active and passive tracks are then interlocked electronically,and are rotated together about 150 degrees in the original direction(Step 9C). Once this process is complete, the braiding machine 100operates to close the transition mechanisms GPA2, GPA4, GPA6 and GPA8(Gate Set A) and continue the braiding process until the next transitionis required.

FIG. 32 illustrates the paths of the bobbin carrier assemblies 122 asthey move through the positions illustrated in FIGS. 23-31 and the tracestrands transition between patterns. In the illustration, the activetrack 202 defines a counterclockwise path 209 (as designated with asingle arrow) and a clockwise carrier path 207 (as designated with adouble arrow), both of which are arranged around a center (axis C) ofthe active track 202. The clockwise and counterclockwise paths 207 and209 are both closed or endless paths, are oscillating, and areout-of-phase from each other. The passive tracks 204A-204D each define afirst transition path 316 (as designated with a striped line) and asecond transition path 318 (as designated with a dotted line). The firsttransition path 316 is configured to move the bobbin carrier assemblies122 from the counterclockwise carrier path 209 to the clockwise carrierpath 207, thereby reversing the direction of the bobbin carrierassemblies 122. The second transition path 318 is configured to move thebobbin carrier assemblies 122 from the clockwise carrier path 207 to thecounterclockwise carrier path 209 also the direction of the bobbincarrier assemblies 122 in the opposite direction.

The movement and positioning of the horn gear assemblies and the bobbincarrier assemblies as they transition the trace strands from one patternto another as illustrated in FIGS. 23-31 is documented in Table1—Operational Sequence of Horn Gear Assemblies.

TABLE 1 Operational Sequence of Horn Gear Assemblies Amount Amount StartStart of of Stop Stop Total Total Position Position Rotation RotationPosition Position Rotation Rotation on on on on on on on on PositionPosition Active Passive Active Passive Active Passive Active Passive ofGate of Gate Step Track Track Track Track Track Track Track Track Set ASet B 1 0 0 0 0 0 0 0 0 Closed Closed 2 0 0 90 90 90 90 90 90 OpenClosed 3 90 90 90 90 180 180 180 180 Open Open 4 180 180 90 90 270 270270 270 Closed Open 5 270 270 90 90 0 0 360 360 Closed Closed 6 0 0 90 090 0 450 360 Closed Open 7 90 0 90 90 180 90 540 450 Closed Open 8A 18090 20 20 200 110 560 470 Closed Closed 8B 200 110 −90 −90 110 20 650 560Closed Open 9A 110 20 −60 0 50 20 700 560 Open Closed 9B 50 20 0 120 50140 700 680 Closed Closed 9C 50 140 150 150 200 290 850 830 ClosedClosed

The start position on the active track (the first column) indicates anangular location of the horn gear assemblies 124 of the active track 202relative to the first location of the horn gear assemblies 124.Similarly, the start position on the passive track (the second column)indicates an angular location of the horn gear assemblies 124 of thepassive track 204 relative to the first location of the horn gearassemblies 124. The amount of the rotation on the active track (thethird column) indicates an amount of the rotation of the active trackmotor 148. Similarly, the amount of the rotation on the passive track(the fourth column) indicates an amount of the rotation of the passivetrack motor 158. The stop position on the active track (the fifthcolumn) indicates the end position of the horn gear assemblies 124 ofthe active track 202 after the horn gear assemblies 124 rotates by theamount of the rotation on the active track from the start position onthe active track. Similarly, the stop position on the passive track (thesixth column) indicates the end position of the horn gear assemblies 124of the passive track 204 after the horn gear assemblies 124 rotates bythe amount of the rotation on the passive track from the start positionon the passive track. The total rotation on the active track (theseventh column) indicates the cumulative amount of rotation of the horngear assemblies 124 of the active track 202. Similarly, the totalrotation on the passive track (the eighth column) indicates thecumulative amount of rotation of the horn gear assemblies 124 of thepassive track 204. The position of the gate set A (the ninth column)indicates the position (either open of closed) of the gates GPA2, GPA4,GPA6, and GPA8. The position of the gate set B (the tenth column)indicates the position (either open of closed) of the gates GPA1, GPA3,GPA5, and GPA7.

In at least some embodiments, the encoders 150 and 160 attached to themotors 148 and 158 (e.g., servo motors) are used to enable the motor 148on the active track 202 to be the master motor and the motor 158 on thepassive track 204 to be the slave motor by electrically gearing the twomotors 148 and 158. In other embodiments, can use different types ofsensor devices to monitor the relative positions of the horn gearassemblies 124 and/or the relative positions of the bobbin carrierassemblies 122 on the active track 202 and/or the passive track 204.Examples of alternative sensor devices include proximity sensors andcameras.

FIGS. 33-35 illustrate example braids 413, 415, and 417 with differentpatterns of one or more trace strands 402. In some embodiments, thetrace strands 402 can have the same color. In other embodiments, thetrace strands 420 can have different colors.

In these embodiments, each of the braids 413, 415, and 417 has aconsistent pattern along the length thereof. In other embodiment, thebraids 413, 415, and 417 can have two or more different patterns thatalternate along the length thereof. Similar to the example braids inFIGS. 19-22, the braids 413, 415, and 417 have no core runningtherealong.

FIG. 33 illustrates an example braid 413 with a cross-striped pattern.The cross-striped pattern is defined by one or more trace strands 412.In at least some embodiments, the cross-striped pattern is generated byusing a single colored trace strand 412. In other embodiments, thecross-striped pattern is generated by using one or more colored tracestrands 412. The plurality of colored trace strands 412 can have anidentical color. In other embodiments, the plurality of colored tracestrands 412 can have different colors to define a multi-colored pattern.Other features of the trace strand(s) 412 and the braid 413 in thisembodiment are the same as those in FIGS. 19-22.

FIG. 34 illustrates an example braid 415 with a parallel-stripedpattern. The parallel-striped pattern can be defined by two or moretrace strands 414 and 416. In at least some embodiments, theparallel-striped pattern is generated by using two trace strands 414 and416 having the same color. In other embodiments, the trace strands 414and 416 can have different colors. Other features of the trace strands414 and 416 and the braid 415 in this embodiment are the same as thosein FIGS. 19-22.

FIG. 35 illustrates an example braid 417 with a crossing pattern. Thecrossing pattern can be defined by two trace strands 418 and 420. In atleast some embodiments, the two trace strands 418 and 420 have the samecolor. In other embodiments, the trace strands 418 and 420 can havedifferent colors. Other features of the trace strands 418 and 420 andthe braid 417 in this embodiment are the same as those in FIGS. 19-22.

FIGS. 36-40 illustrate an example surgical braid having tubular sectionsand a flat section that does not include a bifurcation. Referring now toFIGS. 36 and 37, a surgical braid 500 has two non-flat sections 502 and504 and a flat section 506 therebetween. In at least some embodiments,the non-flat sections 502 and 504 are configured to be out-of-round orcylindrical. In other embodiments, the non-flat sections 502 and 504 areround sections. A flat or tape section 506 is positioned between the twonon-flat sections 502 and 504. The first and second non-flat sections502 and 504 and the tape section 506 are formed with a plurality ofstrands 508 braided into a continuous braid. In at least someembodiments, there is no interruption in the braiding at the transitionbetween the non-flat sections 502 and 504 and the tape section 506. Noris there any splicing, gluing, or other fastening between the non-flatsections 502 and 504 and the tape section 506.

The strands 508 are braided using a 1-over-1 configuration such that thestrands 508 in the non-flat sections 502 and 504 follow a generallyhelical or otherwise spiral path for a full 360°. When the strands 508transition to the tape section 506, the strands 508 in the braid followa helical or otherwise spiral path over an arc that is less than 360°.As they are being braided, the strands 508 in the tape section 506reverse direction, relative to the width of the braid, as they reacheach end of the arc.

In the illustrated embodiment, the surgical braid 500 does not have anybifurcated sections or gaps in either the non-flat sections 502 and 504or the tape section 506. Additionally, there is no core running throughthe non-flat sections 502 and 504 or spine running along or otherwisereinforcing the tape section 506. In some cases, gaps in the braid canreduce the surface area over which the surgical braid 500 exerts forceagainst tissue and thus reduce the distribution of force. Additionally,there is a risk that tissue opposing a gap can enter the gap and bepinched further increasing the risk to trauma. Similarly, a core orspine running along the surgical braid 500 can create a line where forceexerted against the tissue is increased. Eliminating bifurcations, gaps,cores, spines, reinforcing members, and the like enables force exertedagainst tissue by the surgical braid 500 to be distributed over a largerarea and more evenly and also prevents pinching of the tissue therebyreducing trauma.

Referring now to FIG. 38, the circumference of the non-flat sections 502and 504 are initially tubular and have a generally round circumferencewhen initially braided. When in this state, the non-flat sections 502and 504 define an inner channel 510. As explained in more detail herein,the surgical braid 500 can be compressed during manufacturing by thepinch rollers 114A and 114B which reshapes the non-flat sections 502 and504 from a generally round circumference to an oblong circumference. Thecompression increases the width and decreases the height of the non-flatsection. A cross-section for an exemplary embodiment of the non-flatsections 502 and 504 is illustrated in FIG. 39. The out-of-roundcircumference has a width (w) greater than its height (h), and can havea variety of different shapes such as oblong, oval, elliptical, and thelike. Additionally, compressing the non-flat sections 502 and 504 urgesopposing strands 508′ and 508″ in the braid together and substantiallycloses the inner channel 510. In this embodiment, the non-flat sections502 and 504 are not tubular and do not define an inner channel. Otherembodiments are possible. For example, in at least some alternativeembodiments, the non-flat sections 502 and 504 are not compressed by thepinch rollers 114A and 114B and have an open inner channel and aregenerally tubular.

The increased width and oblong shape of the non-flat sections 502 and504 have several functions. For example, this increased width provides asurface area (a′) that is pressed against tissue. The surface area (a′)of the non-flat sections 502 and 504 is larger than the surface area(a″) of a surgical braid 500 having a circular circumference whenpressed against the tissue. The surface area (a′) of the non-flatsections 502 and 504 of the surgical braid 500 provides a distributionof force against tissue that is greater than the distribution of forceprovided by a circular braid, and this greater distribution of forcereduces trauma to tissue. In another example, the oblong shape increasesthe ability of the non-flat sections 502 and 504 to maintain a knot whenthey are tied together during a medical procedure and decreases the riskthat the knot will become inadvertently untied.

Referring to FIGS. 36, 37, and 40 the tape section 506 is substantiallyflat, although the structure of the braid may result in some slightcurvature along the cross section of the tape section 506. The tapesection 506 is substantially wider than the non-flat sections 502 and504. This flat, wide configuration provides greater distribution offorce when the tape section 506 is bound against tissue, which reducestrauma to the tissue. As noted herein, having no bifurcation or gaps inthe braiding of the tape section 506 further reduces the risk of traumato tissue.

FIG. 41 illustrates an alternative embodiment of the surgical braid 500shown in FIG. 36. In this embodiment, the surgical braid 500 has one ormore trace strands 520. The trace strands 520 are braided into thesurgical braid 500 to increase visibility of the surgical braid 500. Atrace strand 520 has a different color than the majority of strands 508used in the surgical braid 500. For example, the surgical braid 500 caninclude a plurality of white strands 522 and one or more color strands520 that visually stand out from the rest of the strands. Examples ofthe color strands include blue strands, green strands, and red strand,and any combination thereof. In the depicted example of FIG. 41, thebraid 500 includes a parallel pattern of two colored strands 520. In atleast some embodiments, the trace strands can be braided into a varietyof different patterns. Additionally, some alternative embodiments willuse both the active track and one or more of the passive tracks duringmanufacturing to transition the trace strands between two or moredifferent patters along the length of the braid.

FIGS. 42 and 43 illustrate the position of the gates 126 and the path ofthe bobbin carrier assemblies when using the arrangement of activetracks, passive tracks, and gates as illustrated in FIG. 3d to make thesurgical braid illustrated in FIGS. 36-40. The path is illustrated usingthe configuration of active tracks, passive tracks, and gatesillustrated in FIG. 3d . When braiding the non-flat sections 502 and504, gates 126A-126H are closed and gates 126I-126P are open so thathalf of the bobbin carrier assemblies travel along the clockwise path207 of the active track and the other half of the bobbin carrierassemblies travel along the counterclockwise path 209 of the activetrack (FIG. 42). To transition to braiding the flat section 506, thegates 126I and 126J are moved to the closed position so that theintra-bridge path of the gates will guide the bobbin carrier assembliesbetween the clockwise and counterclockwise paths of the active track(FIG. 43). To transition back to braiding the non-flat sections 502 and506, the gates are moved back to their open positions so that theinter-track paths of the gates will guide the bobbin carrier assembliesalong the same path and between the adjacent active sub-tracks.

FIG. 44 illustrates an alternative positioning of the gates 126 and pathof the bobbin carrier assemblies for braiding the flat section whenusing the arrangement of active tracks, passive tracks, and gatesillustrated in FIG. 3d . In this arrangement, the gates 126E and 126F(as well as the gates 126K, 126L, 126M, 126J, 126N, and 126S) are in theopen position and the bobbin carriers traveling along the clockwise pathof the active track will be guided to the passive sub-track, to the nextpassive sub-track, and back to the counterclockwise path of the activetrack. Similarly, the gates 126A and 126B (as well as the gates 126K,126L, 126M, 126J, 126N, and 126Q) are in the open position and thebobbin carriers traveling along the counterclockwise path of the activetrack will be guided to the passive sub-track, to the next passivesub-track, and back to the clockwise path of the active track.

FIG. 45 illustrates yet another alternative positioning of the gates 126and path of the bobbin carrier assemblies for braiding the flat sectionwhen using the arrangement of active tracks, passive tracks, and gatesillustrated in FIG. 3d . In this arrangement, the gate 126E, as well asthe gates 126K, 126L, 126M, and 126J, are moved to the open position andthe gates 126N and 126S are in the closed position so that they willguide bobbin carriers traveling along the clockwise path of the activetrack to the passive sub-track and then back to the counterclockwisepath of the active track. Similarly, the gate 126A is open (as well asthe gates 126K, 126L, 126M, and 126J) and the gates 126I and 126Q are inthe closed position so that they will guide bobbin carriers travelingalong the counterclockwise path of the active track to the passivesub-track and then back to the clockwise path of the active track.

FIG. 46 illustrates another alternative embodiment of the surgical braidhaving tubular and flat sections. In this embodiment surgical braid 501is substantially similar to surgical braid 500 illustrated in FIGS.36-40 and also includes two non-flat sections 502 and 504 and a flatsection 506 therebetween. However, the flat section 506 defines abifurcation or gap 530 that divides the flat section 506 into bifurcatedarms 530A and 530B. In at least some embodiments, the surgical braid 500is braided with 16 total strands and each of the two bifurcation arms532A and 532B are braided with 8 strands. Although the surgical braid500 is illustrated having a single bifurcation with two bifurcation arms532 of an equal number of strands. Other embodiment can include morethan one bifurcation. Alternative embodiment might also braid thebifurcation arms with an unequal number of strands, which may change theposition of the bifurcation along the width of the braid. For example,where the surgical braid 500 has two bifurcation arms, one of thebifurcation arms is braided with 4 strands, and the other is braidedwith 12 strands. Additionally, the bifurcated braid illustrated in FIG.46 can include one or more trace strands having a consistent pattern ora changing pattern as described in more detail herein.

The arrangement of active tracks, passive tracks, and gates to braid thenon-flat sections 502 and 504 and the flat section 506 of the surgicalbraid 501 is substantially the same as illustrated in FIGS. 42 and 43.However, when braiding the bifurcations arms 532A and 532B, a second setof gates along the active path are closed to form two closed or endlesspaths along the active track. The number of bobbin carrier assembliestraveling along each endless path will correspond to the number ofstrands in each of the bifurcation arms 532A and 532B. In alternativeembodiments, the passive tracks can be used similar to the arrangementsillustrated in FIGS. 44 and 45 to form the two endless paths for the twogroups of bobbin carrier assemblies.

FIG. 47 illustrates another alternative embodiment of a surgical braidhaving a plurality of leg sections that can be made with braidingmachine 100 as described herein. In this embodiment, a surgical braid530 has a center section 532 having first and second ends 534 and 536. Aplurality of bifurcated leg sections 538A and 538B are connected to thefirst end 534 of the center section 532, and a second plurality ofbifurcated leg sections 540A and 540B are connected to the second end536 of the center section 532. In at least some embodiments, the legsections 538A and 538B, 540A and 540B are flat or tape-like braids. Invarious embodiments, the center section 532 can be formed as a non-flattubular braid or can be a flat or tape-like section. The surgical braid530 can include one or more trace strands having a consistent pattern ora changing pattern as described in more detail herein. The centersection and the bifurcated legs can be made using various arrangementsof active tracks, passive tracks, and gates as described herein to formtubular braids, flat braids, and bifurcated braids.

FIGS. 48-59 illustrate an example surgical braid 600 with sectionshaving different patterns of colors on markings. As described below, thesurgical braid 600 may have different patterns and/or colors of one ormore trace strands. Examples of such patterns and/or colors of the tracestrand 608 are described and illustrated with reference to FIGS. 48-59.

Referring now to FIG. 48, the surgical braid 600 comprises two tubularsections 602 and 604 respectively, which form an outer wall 610 of thesurgical braid 600. A first section 602 and a second section 604 areformed of a plurality of strands 606 braided into a continuous braid.The outer wall 610 of each section 602 and 604 is additionally braidedaround a core section (see FIGS. 49a and 49b ). In the embodimentillustrated, there is no substantial interruption in the braiding at thetransition 614 between sections 602 and 604. Nor is there any splicing,gluing, or other fastening between sections 602 and 604, however in atleast some alternative embodiments, other configurations are possible.

The strands 606 can be braided using a 1-over-1 configuration such thatthe strands 606 in the out-of-round sections 602 and 604 follow agenerally helical or otherwise spiral path for a full 360 degrees. Asused herein, a strand 606 can have a variety of possible structures suchas individual strands or filaments; strands formed with braided ortwisted strands or filaments; and the like. Example materials that canbe used for strands in the surgical braid 600 include those used in thestrands 100 for the braid 108.

In this embodiment, the surgical braid 600 does not have any bifurcatedsections or gaps in either the out-of-round sections 602 and 604.However, in other embodiments, such bifurcations are possible, asillustrated in FIGS. 46 and 47. Additionally, a core 612 (shown in FIGS.49a and 49b ) runs through the out-of-round sections 602 and 604 and atransition area 614. The core 612 is described in more detail herein.

As shown in FIG. 48, the surgical braid 600 includes a trace strand 608.A trace strand 608 is a different color than the majority of strands 606used in the surgical braid 600. A surgical braid can include one or moretrace strands to further enhance visibility of the surgical braid 600.For example, the surgical braid 600 can include a plurality of whitestrands and a color trace strand that visually stands out from the restof the strands. In other embodiments, the surgical braid 600 includes aplurality of white strands, two color strands. In yet other embodiments,the surgical braid 600 includes any combination of a plurality ofstrands, each having a contrasting color to enhance visibility. Examplecolors used for the trace strand 608 include blue, green, violet, brown,purple, black, white, or any other suitable color.

As shown in FIG. 48, the surgical braid is formed of 16 strandsinterbraided in a pattern as described herein. The trace strand 608 isbraided into the outer wall 610 of first section 602 to increasevisibility of the surgical braid 600. The trace strand 608 thentransitions, at a transition point 614, to form the section of the core612 running along the second section 604. The outer wall 610 of thesecond section 604 is braided around the core (the trace strand 608) ofthe second section 604, thereby forming a continuous, surgical braid600. In embodiments described in further detail herein, surgical braids600 can be formed using one or more trace strands 608. In this exampleembodiment, the trace strands 608 do not require splicing, gluing orfastening between sections 602 and 604, however these methods arepossible in alternative embodiments. Additionally, in at least one ofthe possible embodiments, the surgical braid 600 has a length of about36 inches so that the first and second sections 602 and 604 each have alength of about 18 inches. Other embodiments can have different lengths.

FIGS. 49a and 49b show a cross-sectional view of the first section 602and second section 604, respectively, of the surgical braid 600illustrated in FIG. 48. The surgical braid 600 is tubular and has agenerally round circumference. Other possible embodiments includeflattened, oval, or other generally oblong cross-sectional shapes. Asshown, sections 602 and 604 are each formed using 16 strandsinterbraided as described with reference to FIG. 48. As shown in FIG.49a , the single trace strand 608 is braided into the outer wall 610 ofthe first section 602 and at the transition point 614, the trace strand608 is transitioned to form the core 612 of the second section 604.Additionally illustrated in FIG. 48, strand 609 with white, or nodistinguishing color is braided into the outer wall 610 of the secondsection 604 and at the transition point 614, the strand 609 istransitioned to form the core 612 running along the first section 602.As such, the surgical braid 600 shown in FIG. 48 is a continuous braidhaving a single trace strand 608 that transitions from the outer wall610 to the core 612.

FIGS. 50, 51 a and 51 b show an alternative embodiment of the16-filament surgical braid 600 shown in FIG. 48. The surgical braid 601is substantially similar to surgical braid 600 of FIG. 48, however, thewhite strand 609 is replaced with a trace strand 611, which is of acontrasting color.

FIGS. 52 and 53 a-53 c show an alternative embodiment of the 16-filamentsurgical braid 600 shown in FIG. 48. The surgical braid 603 issubstantially similar to surgical braid 600 of FIG. 48. However, shownis an elongated version of the surgical braid 600 including two firstsections 602 alternating with the second section 604. After manufacture,the surgical braid 603 may be cut into smaller surgical braids at linesA and B to form shorter individual surgical braids 605 and 607 having afirst trace strand 608 and a second trace strand 611. This pattern ofalternating sections 602 and 604 and alternating cut lines A and B cancontinue during manufacturing while the strands are being braided andwound onto a take-up reel. The braid is then cut into the surgicalbraids 601 (as shown in FIG. 46) at a later manufacturing stage.

FIGS. 54, 55 a and 55 b show an alternative embodiment of the16-filament surgical braid 600 shown in FIG. 48. A surgical braid 613 issubstantially similar to the surgical braid 600 of FIG. 48. However, thetrace strand 608 is braided into the entire length of the outer wall 610of the surgical braid 613. A second trace strand 611 is additionallybraided into the outer wall 610 of the first section 602 and at atransition point 614, the strand 611 transitions to form the core 612 ofthe second section 604. Additionally, a strand 609 is transitioned, atthe transition point 614, from the core of the first section 602 to theouter wall of the second section 604.

FIGS. 56, 57 a and 57 b show and alternative embodiment of the surgicalbraid 613 illustrated in FIGS. 54, 55 a, and 55 b. In this embodiment, asurgical braid 615 has a different pattern for the first and secondtrace strands 608 and 611. The first trace strand 608 is braided intothe entire length of the outer wall 610 of the surgical braid 613 toform a spiral pattern. The second trace strand 611 is also braided intothe outer wall 610 of the first section 602 to form a spiral patternparallel to the first trace strand 608. At the transition portion 614,the second trace strand 611 transitions to form the core 612 of thesecond section 604. Additionally, the strand 609 is transitioned, at thetransition point 624, from the core of the first section 602 to theouter wall of the second section 604.

FIGS. 58, 59 a and 59 b illustrate an example surgical braid 620, whichis an alternative embodiment of the surgical braid 600 of FIG. 48. Thesurgical braid 620 is substantially similar to the surgical braid 600 ofFIG. 48, except that two trace strands 622 and 624 with contrastingcolor are braided in a pattern. For example, the two trace strands 622and 624 are braided into the outer wall 610 of the first section 602 toform parallel spiral patterns. The trace strands 622 and 624 thentransition at the transition area 614 to form two cores running alongthe second section 604. The outer wall 610 of the second section 604 isbraided around the core formed by the two trace strands 622 and 624.Strands 626 and 628 with white or a color indistinguishable from otherstrands (except the trace strands 622 and 624) are braided into theouter wall 610 of the second section 604. In at least some embodiments,the white strands 626 and 628 are transitioned at the transition area614 to form a core running along the first section 602.

FIGS. 60 and 61 are diagrams schematically illustrating an example path640 of a set of bobbin carriers 640 configured to produce a surgicalbraid with a core, such as illustrated in FIGS. 50-53. The path 640includes two endless paths 642 and 644 to manufacture a surgical braidwith the 612. As depicted, the bobbin carriers are illustrated as 16carriers A-P. The bobbin carriers A-H are positioned on a first endlesspath 642, and the bobbin carriers I-P are positioned on a second endlesspath 644. In operation, the bobbin carriers A-H move along the firstendless path 642 in a direction opposite from the bobbin carriers I-Pthat move along the second endless path 644, thus creating the 1-over-1configuration. Additionally, the bobbin carriers include a middlecarrier Q for forming the core 612 of the braid 600. As shown in FIG.56, the bobbin carriers G and Q hold the two trace strands 608 and 611,respectively. In FIG. 60, the bobbin carrier G holds the trace strand608 that forms the outer wall 610 of the braid 600 and the bobbincarrier Q holds the trace strand 611 that forms the core 612 of thebraid 600. In order to transition the trace strands from the outer wall610 to the core 612 and vice versa, the strands are switched. FIG. 61illustrates a configuration wherein the trace strands 608 and 611 areswitched so that trace strand 608 is placed on bobbin carrier Q, formingthe core 612, and trace strand 611 is placed on bobbin carrier G,forming the outer wall 610. Although the example path 640 is illustratedas moving along 16 horn gear assemblies, surgical braids with a core canbe made using a path that moves along a different number of horn gearassemblies. For example, the path 640 could be formed around a set ofeight horn gear assemblies.

The surgical braids 600, 601, 603, 613, and 620 having a strand thattransitions between a core and being braided into the out wall of thebraid can be made using an arrangement of active tracks, passive tracks,and gates, including those illustrated in FIGS. 3e and 3f . Asillustrated in FIG. 3e , for example, the gate 126 can be moved to theopen position and a passive horn gear assembly corresponding to passivetrack 660 can be rotated to move one bobbin carrier assembly from theactive sub-track 208C and another bobbin carrier from the passive track660 back to the active sub-track 208C. The strand carried by a bobbincarrier assembly positioned along the passive track 660 will form a coreof the surgical braid being produced. Switching bobbin carrierassemblies between the active sub-track 208C and the passive track 660transitions strands between being positioned as the core and beingbraided into the outer wall of the surgical braid. In anotheralternative as illustrated in FIG. 3f , the gates 126 can be opened tomove one of the bobbin carrier assemblies from the active sub-track 208Cto the passive sub-tracks 662 and 661, and also move another bobbincarrier from the passive sub-tracks 661 and 662 back to the activesub-track 208C. Switching bobbin carriers between the active track andthe passive track formed by passive sub-tracks 661 and 662 transitionsstrands between being positioned as the core and being braided into theouter wall of the surgical braid.

FIG. 62 shows a side view of a braid 108, 500, and 600, as describedherein, which is used as a surgical braid. As depicted, the braid 108,500 and 600 can be anchored to a surgical orthopedic anchor 900. In thedepicted example, the surgical braid is anchored to the anchor 900 at,or proximate to, the transition point 410 or 614. In other embodiments,the surgical braid may be anchored at different points, such as abifurcated section or an end of the surgical braid. As shown, thesurgical anchor 900 includes a shaft 902 and one or more threads 904. Insome embodiments, the shaft 902 of the surgical anchor 900 is screwedinto a bone using the threads 904. The surgical braid threaded throughthe anchor 900 is then used for securing ligaments and/or muscles to thebone.

FIGS. 63-81 illustrate yet other possible embodiments of a braider thatcan be used for braiding various surgical braids including surgicalbraid having round and flat portions, alternating patterns of coloredstrands, and alternating cores in tubular sections.

FIG. 63 illustrates an alternative embodiment of a braiding assembly3002 that can be used in the braiding machine 102. In this embodiment,the braiding assembly 3002 includes a braiding track plate 3020, aplurality of bobbin carrier assemblies 122 (including 122A-122P), atleast a first plurality of horn gear assemblies 3032A-3032F, at least asecond plurality of horn gear assemblies 3034A and 3034B, at least onegate 3026, and one or more retraction mechanisms 3050.

As describe in more detail herein, the braiding track plate 3020 issimilar to the braiding track plate 120 and defines a track 3102 (e.g.,FIGS. 65 and 66) configured to guide the plurality of bobbin carrierassemblies 122A-122P along defined paths. The horn gear assemblies3032A-3032F and 3034A and 3034B support and drive the bobbin carrierassemblies 122A-122P along the defined paths. In at least someembodiments, the braiding assembly 3002 is configured and operates toproduce a braid 108. The one or more gate 3026 is configured toselectively guide the bobbin carrier assemblies 122 to automaticallyshift the operation of the braiding assembly 3002 between a roundsection and a flat section of the braid. The structure and operation ofthe gate 3016 is the same as, or similar to, the gates 126A-126Hdescribed herein, except that the dimensions (such as length andcurvature) of inter-track and intra-track paths formed in the gate 3026may be different from those in the gate 126 to match the track 3102underneath the second horn gear assemblies 3034.

The structure and operation of the horn gear assemblies 3032A-3032F inthe first set of horn gears are the same as, or similar to, the horngear assemblies 132A-132H as described herein. The structure andoperation of the horn gear assemblies 3034A and 3034B in the second setof horn gears are also the same as, or similar to, the horn gearassemblies 132A-132H except that the dimensions and number of notches inthe horn gear assemblies 3034A and 3034B can be modified as illustratedand described in more detail herein. In the depicted embodiment, thehorn gear assemblies 3032A-3032F are arranged adjacent one another. Thehorn gear assemblies 3034A and 3034B are adjacent to one another andposition between horn gear assemblies 3032A and 3032F. In thisarrangement, the horn gear assemblies are positioned along the track3102 and about the machine axis C. In the depicted embodiment, the setof first horn gear assemblies 3032 includes six first horn gearassemblies 3032A-3032F. The horn gear assemblies 3032A-3032F, 3034A, and3034B are operated so that that the bobbin carrier assemblies 122A-122Pmove across adjacent horn gear assemblies 3032A-3032H and along thetrack 3102.

The horn gear assemblies 3032A-3032H, 3034A and 3034B are operated in amanner that two adjacent first horn gear assemblies are rotated inopposite direction. For example, the horn gear assemblies 3032A, 3032C,3032E, and 3034B are rotated counter-clockwise while the other horn gearassemblies 3032B, 3032D, 3032F, and 3034A are rotated clockwise, or viceversa. In other embodiments, the first horn gear assemblies 3032A-3032F,3034A, and 3034B can be configured to rotate in different manners. Asdescribed in more detail herein, the first horn gear assemblies 3032 canbe mechanically linked and operated together.

The gate 3026 can be arranged along the track 3102 between the adjacentsecond horn gear assemblies 3034A and 3034B. The gate 3026 can beoperated to enable at least one of the bobbin carrier assemblies122A-122P to move between the adjacent second horn gear assemblies 3034Aand 3034B. Alternatively, the gate 3026 can be operated to prevent atleast one of the bobbin carrier assemblies 122A-122P from crossingbetween the adjacent second horn gear assemblies 3034A and 3034B and tocause the bobbin carrier assembly to move back to the adjacent horn gearassembly to begin moving in the opposite direction (e.g., transitionfrom clockwise to counterclockwise movement, or vice versa, aroundmachine axis C).

The retraction mechanisms 3050 operates to retract at least one of thebobbin carrier assemblies 122 from the horn gear assemblies 3024A and3024B. As described in more detail herein, the retraction mechanisms3050 can cooperate with the gate 3026 to shift between braiding a flatsection of a braid and braiding a tubular section of the braid. Theretraction mechanisms 3050 also can be used to shift between braiding asurgical braid with a core and braiding the braid without a core,alternate or change the strands used as the core along a braid, orchange a pattern or colors of the strands used to form the surgicalbraid.

In the depicted embodiment, the braiding assembly 3002 includes sixfirst horn gear assemblies 3032A-3032F and two second horn gearassemblies 3034A and 3034B, and includes one gate 3026 along a portionof the track 3102 between the two second horn gear assemblies 3034A and3034B. Other embodiments can include different number of horn gearassemblies 3032 and 3034 along the track, a different number of gates3026, or a different number of retraction mechanisms 3050 thanillustrated in the exemplary shown in FIG. 2. There can be a differenttotal number of horn gear assemblies 3032 and 3034, more or fewer thantwo horn gear assemblies 3034, or more or fewer than six horn gearassemblies 3032, or a different ratio between the number of horn gears3034 and the number of horn gears 3032. For example, alternativeembodiments might include two additional horn gears 3034 either between,or in place of, horn gears 3032C and 3032D with a gate between the twoadditional horn gears and additional retraction mechanisms. Suchalternative embodiments would enable braiding of a bifurcated flatsection my moving of some of the bobbin carriers 122 and strands along apath defined from the horn gear 3034A to the additional horn gearlocated in place of horn gear 3032C, and other bobbin carriers 122 andstrands along a path defined from the horn gear 3034B to the additionalhorn gear located in place of horn gear 3032D, Yet other embodimentsmight include yet other additional horn gears 3034 position between orin place of the other horn gears 3032A, 3032B, 3032E, or 3032F. Otherembodiments might include only horn gears 3034 with associated gates3026 and retraction mechanisms 3050.

In the depicted embodiment, the braiding assembly 3002 includes 16bobbin carrier assemblies 122A-122P to produce a 16-end braid 108. Otherembodiments can include any suitable number of bobbin carrier assemblies122 to make braids having any desired numbers of strands. For example,alternative braiding assemblies could have 8, 24, or 32 bobbin carrierassemblies 122, or any other suitable number of bobbin carrierassemblies 122. Further, in the example of FIG. 79, the braidingassembly 3002 includes 17 bobbin carrier assemblies to produce a 17-endbraid having 16 strands as a sheath and one strand as a core.

FIG. 64A is a schematic, top view of an example first horn gear assembly3032. The first horn gear assembly 3032 is configured as a disk 3038having a plurality of slots 3040 (including 3040A-3040D). The slots 3040are configured to engage the bobbin carrier assemblies 1022,respectively. In at some embodiments, the first horn gear assembly 3032has four slots 3040A-3040D that are evenly spaced apart and formed atthe circumference of the disk 3038. In other embodiments, the first horngear assembly 3032 can has one or more slots 3040 (other than fourslots) that are either evenly or unevenly spaced apart around thecircumference of the disk 3038.

Referring to FIGS. 64B and 64C, an example second horn gear assembly3034 is illustrated. The second horn gear assembly 3034 is configured asa disk 3042 or 3046 having a plurality of slots. The plurality of slotsis configured to engage the bobbin carrier assemblies 1022,respectively. The plurality of slots are formed at the circumference ofthe disk and arranged such that at least some of the slots areselectively used to provide either an even number of evenly spaced slotsaround the disk 3042 or 3046 or an odd number of evenly spaced slotsaround the disk 3042 or 3046. As described herein, the even number ofevenly spaced slots can be used to create a round section of a braid108, and the odd number of evenly spaced slots can be used to braid aflat section of the braid 108.

FIG. 64B is a schematic, top view of an example second horn gearassembly 3034. In this example, the second horn gear assembly 3034 isshaped as a disk 3042 having eight slots 3044A-3044H. The slots 3044A,3044C, 3044E, and 3044G are evenly spaced apart in about 90 degreeincrements around the disk 3042 to form a set of four evenly spacedslots (an even number of slots), although alternative embodiment canhave an angular spacing other than 90 degrees. Further, the slots 3044A,3044B, 3044D, 3044F, and 3044H are evenly spaced apart in about 72degree increments around the disk 3042 to form a set of five evenlyspaced slots (an odd number of slots), although alternative embodimentcan have an angular spacing other than 72 degrees. As such, the set offour evenly spaced slots shares one slot (the slot 3044A) with the setof five evenly spaced slots. In at least some embodiments, the disk 3042of the second horn gear assembly 3034 has a radius R2 that is greaterthan a radius R1 of the disk 3038.

FIG. 64C is a schematic, top view of another example second horn gearassembly 3034. In this example, the second horn gear assembly 3034 isshaped as a disk 3046 having six slots 3048A-3048F. The slots 3048A,3048B, 3048C, 3048D, 3048E, and 3048F are evenly spaced apart in about60 degree increments around the disk 3046 to form a set of six evenlyspaced slots (an even number of slots), although alternative embodimentcan have an angular spacing other than 60 degrees. Further, the slots3048A, 3048C, and 3048E are evenly spaced apart in about 120 degreeincrements around the disk 3046 to form a set of three evenly spacedslots (an odd number of slots), although alternative embodiment can havean angular spacing other than 120 degrees. The set of six evenly spacedslots shares three slots (the slots 3048A, 3048C, and 3048E) with theset of three evenly spaced slots. In at least some embodiments, the disk3046 of the second horn gear assembly 3034 has a radius R3 that isgreater than a radius R1 of the disk 3038.

In other embodiments, the second horn gear assembly 3034 is configuredas a disk having a different size and a different number of slots. It isstill noted that the slots of the second horn gear assembly 3034 arearranged such that at least some of the slots are selectively used toprovide either an even number of evenly spaced slots or an odd number ofevenly spaced slots.

FIG. 65A illustrates the embodiment of the track plate 3020 and thetrack 3102 as discussed with reference to FIG. 63. In this embodiment,the gate 3026 is in an open position. The track plate 3020 is a platethat defines a plurality of slots or grooves 3104 that form the track3102. The track 3102 is formed to correspond to the first and secondhorn gear assemblies 3032A-3032F and 3034A-3034B and guide the bobbincarrier assemblies 122A-122P as they are propelled by the first andsecond horn gear assemblies 3032A-3032F and 3034A-3034B as explained inmore detail herein. The track 3102 includes eight sub-tracks (i.e., sixfirst sub-tracks 3108A-3108F and two second sub-tracks 3110A-3110B),which correspond to the first and second horn gear assemblies3032A-3032F and 3034A-3034B, respectively. The sub-tracks 3108A-3108Fand 3110A-3110B are arranged abutted to each other around the machineaxis C so that the bobbin carrier assemblies 1022A-1022P selectivelymove between adjacent sub-tracks 3108A-3108F and 3110A-3110B as theymove along the track 3102.

The gate 3026 is positioned between the second sub-tracks 3110A and3110B. The gate 3026 has an open position and a closed position anddefine grooves or slots for guiding the bobbin carrier assemblies122A-122P either between the second sub-tracks 3110A and 3110B, or alongone of the second sub-tracks 3110A and 3110B and pass the other.

Referring to FIG. 65A, the gate 3026 is in the open position at whichthe bobbin carrier assemblies 122A-122P are guided by the inter-bridgepath of the gate 3026 to move between the second sub-tracks 3110A and3110B as they are propelled by the second horn gear assemblies3034A-3034B. Thus, as illustrated in FIG. 65B, the track 3102 provides aclockwise path 3112 and a counter clockwise path 3114, each of whichoscillates and is out-of-phase from the other. When the gate 3026 is inthe open position, the braiding assembly 3002 operates to carry half ofthe bobbin carrier assemblies 122 along the clockwise path 3112 and theother half of the bobbin carrier assemblies 122 along the counterclockwise path 3114 in order to braid a non-flat (e.g., round) sectionof a braid 108, as illustrated in FIG. 68.

FIG. 66A illustrates the embodiment of the track plate 3020 and thetrack 3102 with the gate 3026 in the closed position. When the gate 3026is in the closed position, the intra-bridge path of the gate 3026 willguide the bobbin carrier assemblies 122A-122P along clockwise andcounterclockwise paths 3116 and 3118 of the track 3020 (FIG. 66B) suchthat the bobbin carrier assemblies 122A-122P remain in one of the secondsub-tracks 3110A and 3110B, along which they are traveling, and pass theother of the second sub-tracks 3110A and 3110B. The clockwise path 3116is similar to the clockwise path 3112, and the counterclockwise path3118 is similar to the clockwise path 3114. However, when the gate 3026is in the closed position, the bobbin carrier assemblies 122 areprevented from continuing to move along either the clockwise path 3112or the counterclockwise path 3114 past the gate 3026, and are guided bythe gate 3026 to move from the clockwise path 3116 and thecounterclockwise path 3118 across the gate 3026, or vice versa. As such,when the gate 3026 is in the closed position, a single oscillatingclosed, endless path is formed with the clockwise and counterclockwisepaths 3116 and 3118. When the gate 3026 is in the closed position, thebraiding assembly 3002 operates to braid a flat section of the braid108, as illustrated in FIG. 68.

FIG. 67 is a schematic diagram of an example braiding control system3120 for the braiding machine 100 including the braiding assembly 3002.In at least some embodiments, the braiding control system 3120 isdesigned similarly to the control system 240 as illustrated in FIG. 17A.As many of the concepts and features are similar to the embodiment shownin FIG. 17A, the description for the embodiment illustrated in FIG. 17Ais hereby incorporated by reference for an embodiment of the braidingcontrol system 3120. Where like or similar features or elements areshown, the same reference numbers will be used where possible. Thefollowing description for the braiding control system 3120 will belimited primarily to the differences between the control system 240 andthe braiding control system 3120.

As illustrated in FIG. 67, in at least some embodiments, the set of thefirst horn gear assemblies 3032A-3032F is operated by a first motor 148,and the set of the second horn gear assemblies 3034A and 3034B isoperated by a second motor 158. The gate 3026 can be actuated by a gateactuating system 164 (e.g., a solenoid or motor system). The retractionmechanisms 3050 can be actuated by retraction operation systems 3056(e.g., a solenoid or motor system), respectively. In some embodiments,the retraction mechanisms 3050 can be operated by a single retractionoperation system 3056.

FIG. 68 illustrates an example braid 108 that can be made using thebraiding machine 100 with the braiding assembly 3002. In at least someembodiments, the braid 108 has two non-flat sections 3132 and 3134 and aflat section 3136 therebetween. The braid 108 can be braided similarlyto the braid 500, as explained FIGS. 36 and 41.

In at least some embodiments, the non-flat sections 3132 and 3134 areconfigured to be out-of-round or cylindrical. In other embodiments, thenon-flat sections 3132 and 3134 are round sections. A flat or tapesection 3136 is positioned between the two non-flat sections 3132 and3134. The first and second non-flat sections 3132 and 3134 and the tapesection 3136 are formed with a plurality of strands 3138 braided into acontinuous braid. In at least some embodiments, there is no interruptionin the braiding at the transition between the non-flat sections 3132 and3134 and the tape section 3136. Nor is there any splicing, gluing, orother fastening between the non-flat sections 3132 and 3134 and the tapesection 3136.

The strands 3138 are braided using a 1-over-1 configuration such thatthe strands 3138 in the non-flat sections 3132 and 3134 follow agenerally helical or otherwise spiral path for a full 360°. When thestrands 3138 transition to the tape section 3136, the strands 3138 inthe braid 108 follow a helical or otherwise spiral path over an arc thatis less than 360°. As they are being braided, the strands 3138 in thetape section 3136 reverse direction, relative to the width of the braid,as they reach each end of the arc. In the illustrated embodiment, thesurgical braid 108 as illustrated in FIG. 68 does not have anybifurcated sections or gaps in either the non-flat sections 3132 and3134 or the tape section 3136. Additionally, there is no core runningthrough the non-flat sections 502 and 504 or spine running along orotherwise reinforcing the tape section 506.

Although the braid 108 is illustrated in FIG. 68 to have two non-flatsections 3132 and 3134 and one flat section 3136 therebetween, otherembodiments are also possible that the braid 108 has a plurality of flatsections 3136 and a plurality of non-flat section 3132 and 3134, whichare alternately arranged each other.

FIGS. 69-71 illustrate an example operation of the braiding assembly3002 for transitioning between flat and non-flat sections of the braid108, which is described in FIG. 68. In particular, FIG. 69 illustratesexample positions of the horn gear assemblies 3032A-3032F and3034A-3034B of the braiding assembly 3002, which is in a transitionstart position. FIG. 70 illustrates example positions of the horn gearassemblies 3032A-3032F and 3034A-3034B of the braiding assembly 3002,which is in an intermediate transition position. FIG. 71 illustratesexample positions of the horn gear assemblies 3032A-3032F and3034A-3034B of the braiding assembly 3002, which is in a transition endposition. As described herein, when the braiding assembly 3002 movesfrom the transition start position to the transition end portion throughthe intermediate transition position, the braid 108 transitions from aflat section to a non-flat section. Similarly, the braid 108 cantransition from a non-flat section to a flat section when the braidingassembly 3002 operates in the opposite steps (i.e., when the braidingassembly 3002 moves from the transition end position to the transitionstart position through the intermediate transition position). Forpurposes of illustration, the steps and bobbin carrier positions inFIGS. 69-71 are shown using the arrangement of the track, horn gearassemblies, and gate illustrated in FIGS. 63-66, although the steps oroperations described herein can be implemented with alternativearrangements of the passive track, horn gear assemblies, and one or moregates.

The horn gear assemblies 3032A-3032F and 3034A-3034B operate in a mannersimilar to the horn gear assemblies 132A-132H, as illustrated in FIGS.23-31, except for the passive horn gears 134A-134H. The eight horn gearassemblies 3032A-3032F and 3034A-3034B operate to carry bobbin carrierassemblies 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B, 5A, 5B, 6A, 6B, 7A, 7B, 8A,and 8B, which roughly correspond to the bobbin carrier assemblies122A-122P. As described below, the horn gear assemblies also operate toselectively transfer at least one of the bobbin carrier assembliesbetween adjacent horn gear assemblies as the horn gear assembliesrotate. In at least some embodiments, shifts of the bobbin carrierassemblies between adjacent active horn gear assemblies occur attransition positions therebetween. The bobbin carrier assemblies can beselectively shifted between the second horn gear assemblies 3034A and3034B through a transition mechanism, which can be configured as thegate 3026. In the depicted example of FIG. 69 in which the braidingassembly 3002 operates to braid a flat section of a braid, a first setof bobbin carrier assemblies 1A,2A, 3A, 4A, 5A, 6A, 7A, and 8A movesalong one of the clockwise path 3116 and the counterclockwise path 3118,and a second set of bobbin carrier assemblies 1B, 2B, 3B, 4B, 5B, 6B,7B, and 8B moves along the other of the clockwise path 3116 and thecounterclockwise path 3118. In the depicted example of FIG. 71 in whichthe braiding assembly 3002 operates to braid a non-flat section of abraid, the first set of bobbin carrier assemblies 1A,2A, 3A, 4A, 5A, 6A,7A, and 8A moves along one of the clockwise path 3112 and thecounterclockwise path 3114, and the second set of bobbin carrierassemblies 1B, 2B, 3B, 4B, 5B, 6B, 7B, and 8B moves along the other ofthe clockwise path 3112 and the counterclockwise path 3114.

Referring to FIG. 69, the braiding assembly 3002 is in a transitionstart position at which the braiding assembly 3002 is ready totransition from braiding a flat section 3136 to a non-flat section 3132or 3134. Until the braiding assembly 3002 reaches the transition startposition as depicted in FIG. 69, the braiding assembly 3002 operates tobraid a flat section of the braid 108 with a 1-over-1 configuration. Inparticular, the second horn gear assemblies 3034A and 3034B are operatedsuch that an odd number of evenly spaced slots are used to braid a flatsection of the braid 108. In at least some embodiments, five slots3044A, 3044B, 3044D, 3044F, and 3044H, which are evenly spaced apart inabout 72 degree increments, are selected for a flat section braiding,although alternative embodiment can have an angular spacing other than72 degrees. Further, the gate 3026 is closed between the second horngear assemblies 3034A and 3034B for braiding a flat section of the braid108. The horn gear assemblies operate to carry the eight horn gearassemblies along the clockwise path 3116 and the counterclockwise path3118 of the track 3102 (FIGS. 66A and 66B). The horn gear assemblies3032A-3032F and 3034A-3034B are configured to have a speed profile thatmatches the four slots 3040A-3040D of the first horn gear assemblies3032A-3032F and the five slots 3044A, 3044B, 3044D, 3044F, and 3044H ofthe second horn gear assemblies 3034A and 3034B between two adjacentones of the first and second horn gear assemblies 3032A-3032F and3034A-3034B.

To transition from a flat section braiding to a non-flat sectionbraiding, the braiding assembly 3002 is paused in the transition startposition, as illustrated in FIG. 69. Once the braiding assembly 3002 isin the transition start position, the gate 3026 between the second horngear assemblies 3034A and 3034B is opened. Further, the bobbin carrierassemblies 1A, 1B, and 8B are retracted from the associated second horngear assemblies 3034A and 3034B, as illustrated in FIG. 70. In someembodiments, the retraction mechanisms 3050 (FIG. 72) are used toretract the bobbin carrier assemblies 1A, 1B, and 8B, as illustratedherein.

Referring to FIG. 70, the bobbin carrier assemblies 1A and 1B areretracted from the associated slots 3044D and 3044H of the second horngear assembly 3034A, and the bobbin carrier assembly 8B is retractedfrom the associated slot 3044B of the second horn gear assembly 3034B,such that the braiding assembly 3002 is in an intermediate transitionposition. In the intermediate transition position, the bobbin carrierassemblies 1A, 1B and 8B, which have been retracted, are clear of thehorn gear assemblies when the horn gear assemblies rotate. In at leastsome embodiments, the retraction mechanism 3050 (FIG. 72) is used tomechanically retract the bobbin carrier assemblies 1A, 1B and 8B fromthe associated slots of the second horn gear assemblies 3034A and 3034B.An example of the retraction mechanism 3050 is illustrated and describedwith reference to FIG. 72.

Once the braiding assembly 3002 is in the intermediate transitionposition (i.e., the bobbin carrier assemblies 1A, 1B, and 8B areretracted from the associated second horn gear assemblies 3034A and3034B), the horn gear assemblies 3032A-3032F and 3034A-3034B rotate suchthat the slot 3044C of the second horn gear assembly 3032B is alignedwith the bobbin carrier assembly 8B. In the depicted example, the horngear assemblies 3032A-3032F and 3034A-3034B rotate about 18 degrees,respectively, such that the second horn gear assembly 3034B rotatesabout 18 degrees in a counterclockwise direction, although alternativeembodiment can have an angular movement other than 18 degrees. Then, thebobbin carrier assembly 8B moves toward the horn gear assembly 3034B soas to engage the slot 3044C of the second horn gear assembly 3034B. Thebobbin carrier assembly 8B switches from the slot 3044B to the slot3044C of the second horn gear assembly 3034B. The retraction mechanism3050 can be used to insert the bobbin carrier assembly 8B into the slot3044C of the second horn gear assembly 3034B.

Once the horn gear assemblies 3032A-3032F and 3034A-3034B rotate suchthat the bobbin carrier assembly 8B is switched from the slot 3044B tothe slot 3044C of the second horn gear assembly 3032B, the horn gearassemblies 3032A-3032F and 3034A-3034B rotate in the opposite directionsuch that the slot 3044G of the second horn gear assembly 3034A isaligned with the bobbin carrier assembly 1B. In the depicted example,the horn gear assemblies 3032A-3032F and 3034A-3034B rotate 36 aboutdegrees, respectively, in the opposite direction such that the secondhorn gear assembly 3034A rotates about 36 degrees in a counterclockwisedirection, although alternative embodiment can have an angular movementother than 36 degrees. Then, the bobbin carrier assembly 1B moves towardthe horn gear assembly 3034A so as to engage the slot 3044G of thesecond horn gear assembly 3034A. Therefore, the bobbin carrier assembly1B switches from the slot 3044H to the slot 3044G of the second horngear assembly 3034A. Similarly, the retraction mechanism 3050 can beused to insert the bobbin carrier assembly 1B into the slot 3044G of thesecond horn gear assembly 3034A.

Once the horn gear assemblies 3032A-3032F and 3034A-3034B rotate suchthat the bobbin carrier assembly 1B is switched from the slot 3044H tothe slot 3044G of the second horn gear assembly 3032A, the horn gearassemblies 3032A-3032F and 3034A-3034B rotate such that the slot 3044Eof the second horn gear assembly 3034A is aligned with the bobbincarrier assembly 1A. In the depicted example, the horn gear assemblies3032A-3032F and 3034A-3034B rotate about 54 degrees, respectively, inthe direction opposite to the previous rotation such that the secondhorn gear assembly 3034A rotates about 18 degrees in a clockwisedirection, although alternative embodiment can have an angular movementother than 54 or 18 degrees, respectively. Then, the bobbin carrierassembly 1A moves toward the horn gear assembly 3034A so as to engagethe slot 3044E of the second horn gear assembly 3034A. Therefore, thebobbin carrier assembly 1A switches from the slot 3044D to the slot3044E of the second horn gear assembly 3034A. Similarly, the retractionmechanism 3050 can be used to insert the bobbin carrier assembly 1A intothe slot 3044E of the second horn gear assembly 3034A. The finalpositions of the bobbin carrier assemblies relative to the horn gearassemblies are illustrated in FIG. 71.

Referring to FIG. 71, the horn gear assemblies 3032A-3032F and3034A-3034B of the braiding assembly 3002 is in a transition endposition. Beginning from the transition end position, the second horngear assemblies 3034A and 3034B are operated such that an even number ofevenly spaced slots are used to braid a non-flat section of the braid108. In at least some embodiments, four slots 3044A, 3044C, 3044E, and3044G, which are evenly spaced apart in about 90 degree increments, areselected for a non-flat section braiding, although alternativeembodiment can have an angular spacing other than 90 degrees. Further,the gate 3026 remains open between the second horn gear assemblies 3034Aand 3034B for braiding a non-flat section of the braid 108. Therefore,the horn gear assemblies operate to carry the eight horn gear assembliesalong the clockwise path 3112 and the counterclockwise path 3114 of thetrack 3102 (FIG. 65). The horn gear assemblies 3032A-3032F and3034A-3034B also changes to have a speed profile that matches the fourslots 3040A-3040D of the first horn gear assemblies 3032A-3032F and thefour slots 3044A, 3044C, 3044E, and 3044G of the second horn gearassemblies 3034A and 3034B between two adjacent ones of the first andsecond horn gear assemblies 3032A-3032F and 3034A-3034B.

In other embodiments, the steps performed from the transition startposition to the transition end position can change as necessary to theextent that the bobbin carrier assemblies engaged in one or more of anodd number of evenly spaced slots of the second horn gear assemblies3034A and 3034B have shifted to one or more of an even number of evenlyspaced slots of the same second horn gear assemblies 3034A and 3034B.

Although it is described that all of the horn gear assemblies3032A-3032F and 3034A-3034B are operated to rotate together in thetransition stage, it is possible to permit only some of the horn gearassemblies 3032A-3032F and 3034A-3034B to rotate as necessary. In theembodiments where the first horn gear assemblies 3032A-3032F areoperated together by a single motor and the second horn gear assemblies3034A-3034B are actuated together by another single motor, the secondhorn gear assemblies 3034A-3034B can be operated to rotate together, butindependently from the first horn gear assemblies 3032A-3032F.

The steps described above with reference to FIGS. 69-71 are reversed totransition from braiding a non-flat section to braiding a flat sectionof the braid 108.

FIGS. 72-78 schematically illustrate example configuration of aretraction mechanism 3050. The retraction mechanism 3050 is configuredto enable a bobbin carrier assembly 122 to switch slots of the secondhorn gear assembly 3034. For brevity purposes, the bobbin carrierassembly 122 is only partially illustrated to clearly show configurationand operation of the retraction mechanism 3050.

FIG. 72 is a schematic perspective view of an example retractionmechanism 3050. The retraction mechanism 3050 can include a retractionbody 3054 defining a track path 3055. The track path 3055 is configuredto receive the carrier guide 176 (e.g., the keels 182A and 182B) of thebobbin carrier assembly 122 that moves along the track 3102 of thebraiding track plate 3020. In some embodiments, the track path 3055 hasthe same dimensions (such as width and curvature) as those of the track3102 to which the retraction mechanism 3050 is arranged adjacent. In theillustrated example, as the retraction mechanism 3050 is arranged withthe second sub-tracks 3110A-3110B, the track path 3055 has the samewidth and curvature as the groove of the second sub-tracks 3110A-3110B.The track path 3055 is formed in the retraction body 3054 to be alignedwith the track 3102 of the braiding track plate 3020 when the retractionmechanism 3050 is in a non-retracted position (FIG. 73). In thenon-retracted position, the track path 3055 of the retraction mechanism3050 functions as a portion of the track 3102 so that the bobbin carrierassemblies continuously moves along the track path 3055 of theretraction mechanism 3050 and the remainder of the track 3102. When theretraction mechanism 3050 is in a retracted position (FIG. 74), thetrack path 3055 operates to hold the carrier guide 176 of the bobbincarrier assembly 122 out of the track 3102. As described herein, theretraction mechanism 3050 is actuated by the retraction operation system3056 that includes either a solenoid or a motor.

FIGS. 73A-73C schematically illustrate an example operation of theretraction mechanism 3050. In FIG. 73A, the retraction mechanism 3050 isin a non-retracted position. In the depicted example of FIG. 73A, thebobbin carrier assembly 122 is inserted in the slot 3044G of the horngear assembly 3034. As illustrated in FIG. 73B, the bobbin carrierassembly 122 is guided by the associated horn gear assembly 3034 to movealong the track 3102 toward the track path 3055 of the retractionmechanism 3050. In particular, the carrier guide 176 (such as the keels182A and 182B) is guided by the track 3102 toward the track path 3055that is aligned with the track 3102. Referring to FIG. 73C, the carrierguide 176 of the bobbin carrier assembly 122 slides into the track path3055 of the retraction mechanism 3050 so that the bobbin carrierassembly 122 is arranged as illustrated in FIG. 73A.

The retraction mechanism 3050 is configured to selectively retract thebobbin carrier assembly 122 from the associated horn gear assembly 3034so that the retracted bobbin carrier assembly 122 is clear of thespinning horn gear assembly 3034. In at least some embodiments, theretraction mechanism 3050 is configured to slidably move in a radialdirection with respect to the horn gear assembly 3034. In at least someembodiments, the track plate 3020 includes a guiding mechanism 3052(e.g., a groove or channel) configured to guide movement of theretraction mechanism 3050.

FIGS. 74A-74C schematically illustrate the retraction mechanism 3050 ofFIGS. 73A-73C when the retraction mechanism 3050 is in a retractedposition, in which the retraction mechanism 3050 retracts the bobbincarrier assembly 122 from the slot 3044G of the horn gear assembly 3034.In this position, the horn gear assembly 3034 can freely rotate and thebobbin carrier assembly 122 does not interfere with the rotation of thehorn gear assembly 3034. For example, when the carrier guide 176 (suchas the keels 182A and 182B) moves into the track path 3055 of theretraction mechanism 3050, the retraction mechanism 3050 is displacedradially outwardly by the retraction operation system 3056 such that theretracted bobbin carrier assembly 122 is clear of the rotating horn gearassembly 3034. FIG. 74C illustrates the position of the carrier guide176 of the bobbin carrier assembly 122 relative to the retractionmechanism 3050 and the track 3102.

FIG. 75 schematically illustrates the retraction mechanism 3050 of FIGS.73A-73C when the horn gear assembly 3034 rotates at a predeterminedamount of rotation. In the depicted example, the horn gear assembly 3034rotates about 18 degrees clockwise so that the slot 3044H is alignedwith the bobbin carrier assembly 122, although alternative embodimentcan have an angular movement other than 18 degrees.

FIGS. 76A and 76B schematically illustrate the retraction mechanism 3050of FIGS. 73A-73C when the retraction mechanism 3050 operates to insertthe bobbin carrier assembly 122 to the slot 3044H of the horn gearassembly 3034. In this position, the retraction mechanism 3050 movestoward the horn gear assembly 3034 to carry the bobbin carrier assembly122 into the slot 3044H when the horn gear assembly 3034 rotates toalign the slot 3044H with the bobbin carrier assembly 122.

In at least some embodiments, the braiding assembly 3002 can include oneretraction mechanism 3050 configured to selectively retract and insertone or more bobbin carrier assemblies. In other embodiments, thebraiding assembly 3002 can include a plurality of retraction mechanisms3050 for selectively retract and insert one or more bobbin carrierassemblies. For example, there may be four retraction mechanisms 3050arranged adjacent the second horn gear assemblies 3034A and 3034B.

As illustrated in FIG. 67, the retraction mechanism 3050 can be operatedby a retraction operation system 3056. In some embodiments, theretraction operation system 3056 can include one or more solenoids ofany type, such as electromechanical solenoids, rotary solenoids, rotaryvoice coils, pneumatic solenoid valves, and hydraulic solenoid valves.In other embodiments, the retraction operation system 3056 can include apneumatic operating system. For example, the pneumatic operating systemcan include a pneumatic indexer, rack and pinion arrangement or a belt.In yet other embodiments, the retraction operation system 3056 caninclude a motor, such as a servo or stepper motor.

FIG. 77 is a schematic perspective view of another example retractionmechanism 3050. The retraction mechanism 3050 in this example issubstantially the same as the retraction mechanism 3050 as illustratedin FIG. 72 except for a secondary track path 3058. As described herein,the track path 3055 is configured to align the track 3102 of thebraiding track plate 3020 when the retraction mechanism 3050 is in thenon-retracted position. The secondary track path 3058 is configured toalign the track 3102 of the braiding track plate 3020 when theretraction mechanism 3050 is in the retracted position. For doing so,the secondary track path 3058 can have the same dimensions (such aswidth and curvature) as those of the track 3102 to which the retractionmechanism 3050 is arranged adjacent. When the retraction mechanism 3050is in the retracted position, the secondary track path 3058 enables thebobbin carrier assemblies to move along the track 3102 across thesecondary track path 3058.

FIGS. 78A-78C schematically illustrate an example operation of theretraction mechanism 3050 of FIG. 77. Referring to FIG. 78A, theretraction mechanism 3050 is in the non-retraction position, and twobobbin carrier assemblies 122 approach the retraction mechanism 3050. Inparticular, two carrier guides 176 (such as the keels 182A and 182B) ofthe bobbin carrier assemblies 122 are guided by the track 3102 towardthe track path 3055 that is aligned with the track 3102. Referring toFIG. 78B, one of the carrier guides 176 slides into the track path 3055of the retraction mechanism 3050. Referring to FIG. 78C, the retractionmechanism 3050 is radially outwardly shifted to its retracted position,in which the secondary track path 3058 aligns the track 3102 of thebraiding track plate 3020. The other carrier guide 176 of the bobbincarrier assembly 122 can slide into the secondary track path 3058 topass the retraction mechanism 3050.

Operation of the retraction mechanism 3050 having two paths enables abobbin carrier to be moved off the track so that another bobbin carriercan move pass it thereby changing the sequence or order of the bobbincarriers and strands as they move around the track. Changing thesequence or order of the bobbin carriers or strands while braiding asurgical braid will change the pattern of the strands forming the braidsas described herein. Operations that change the sequence or order of thebobbin carriers and strands to change the pattern of the strands can beperformed using the embodiments illustrated in FIGS. 63-81 as well asother embodiments including the other embodiments illustrated anddescribe herein and other braiders that may not be illustrated ordescribed herein.

FIGS. 79A-79C illustrates an example braid 108 that can be made usingthe braiding machine 100 with the braiding assembly 3002. The braid 108as illustrated in FIGS. 79A-79C is similar to the braid 108 asillustrated in FIG. 68, except for an additional strand 3060 runningthrough the braid 108. The additional strand 3060 can also be referredto herein as a trace strand 3060.

Similarly to the braid 108 in FIG. 68, the braid 108 in this embodimenthas two non-flat sections 3132 and 3134 and a flat section 3136therebetween. The configuration of the non-flat sections 3132 and 3134and the flat section 3136 of the braid 108 is the same as those of thebraid 108 as illustrated in FIG. 68. Although the braid 108 isillustrated in FIG. 68 to have two non-flat sections 3132 and 3134 andone flat section 3136 therebetween, other embodiments are also possiblethat the braid 108 has a plurality of flat sections 3136 and a pluralityof non-flat section 3132 and 3134, which are alternately arranged eachother.

As described herein, the braid 108 as illustrated in FIG. 68 is formedof 16 strands interbraided in a 1-over-1 configuration. The trace strand3060 as illustrated in FIGS. 79A-79C is another strand added into the16-strand braid. As such, the braid 108 as illustrated in FIGS. 79A-79Cis formed of 17 strands.

In some embodiments, the trace strand 3060 is braided into an outer wallof the first non-flat section 3132 to increase visibility of the braid108, which can be used for medical purposes (e.g., as a surgical braid).The trace strand 3060 then runs through the flat section 3136 of thebraid 108 to further add visibility of the braid 108. The trace strand3060 forms a core 3064 (FIGS. 80A and 80B) running along the secondnon-flat section 3134. For example, the outer wall of the secondnon-flat section 3134 is braided around the core 3064, thereby forming acontinuous braid. In this configuration, the core 3064 is formed withthe trace strand 3060 at the second non-flat section 3134. In otherembodiments, braids 108 can be formed using one or more trace strands3060. In these example embodiments, the trace strand(s) 3060 do notrequire splicing, gluing or fastening between flat and non-flatsections, however these methods are possible in alternative embodiments.

Referring to FIG. 79A, the braid 108 is formed of 17 strands including afirst color strand 3060 and a second color strand 3062. The first andsecond color strands 3060 and 3062 have different colors from theremaining strands (15 strands). For example, the first color strand 3060can have blue and the second color strand 3062 can have black while theother strands are white. The colors of the strands can change asnecessary. At the first non-flat section 3132, the first color strand3060 is braided into an outer wall of the first non-flat section 3132,and the second color strand 3062 forms a core 3064. At the secondnon-flat section 3134, the first color strand 3060 forms a core 3064 andthe second color strand 3062 is braided into an outer wall of the secondnon-flat section 3132. The first and second color strands 3060 and 3062run through the flat section 3136 so as to be arranged in parallel. Thefirst and second color strands 3060 and 3062 can be spaced at variousmanners through the flat section 3136. In the illustrated example, thefirst and second color strands 3060 and 3062 run in parallel with onestrand therebetween. In other embodiments, the first and second colorstrands 3060 and 3062 are spaced with more than one strandstherebetween, or arranged to about each other without a strandtherebetween. To form the parallel pattern, a bobbin carrier assembly112 supplying the first color strand 3060 and a bobbin carrier assemblysupplying the second color strand 3061 are relatively positioned totravel along the track 3102 in the same direction (either clockwise orcounterclockwise).

Referring to FIG. 79B, the braid 108 is formed of 17 strands includingthe first color strand 3060 and the second color strand 3062. At thefirst non-flat section 3132, the first color strand 3060 is braided intoan outer wall of the first non-flat section 3132, and the second colorstrand 3062 forms a core 3064. At the second non-flat section 3134, thefirst color strand 3060 forms a core 3064 and the second color strand3062 is braided into an outer wall of the second non-flat section 3132.The first and second color strands 3060 and 3062 run through the flatsection 3136 so as to form a cross pattern. The first and second colorstrands 3060 and 3062 can run to cross each other in various mannersthrough the flat section 3136. In the illustrated example, the first andsecond color strands 3060 and 3062 run to cross each othersymmetrically. In other embodiments, other cross patterns are possible.To form the cross pattern, a bobbin carrier assembly 112 supplying thefirst color strand 3060 and a bobbin carrier assembly supplying thesecond color strand 3061 are relatively positioned to travel along thetrack 3102 in the opposite directions. For example, when the bobbincarrier assembly 112 holding the first color strand 3060 moves clockwisealong the track 3102, the bobbin carrier assembly 112 holding the secondcolor strand 3062 is configured to travel counterclockwise.

Referring to FIG. 79C, the braid 108 is formed of 17 strands including asingle color strand 3060. The color strand 3060 has a color differentfrom that of the other 16 strands. In other words, the second colorstrand 3062 has the same color as that of the remaining 15 strands. Asillustrated, the color strand 3060 is braided into an outer wall of thefirst non-flat section 3132, runs through the non-flat section 3136, andforms a core 3064 at the second non-flat section 3134. As such, thebraid 108 shown in FIG. 79C is a continuous braid having a single tracestrand 3060 that transitions from the outer wall of the non-flat sectionto the core of the next non-flat section with the flat sectiontherebetween.

FIGS. 80A-80C show cross-sectional views of the first non-flat section3132, the second non-flat section 3134, and the non-flat section 3136,respectively, of the braid 108 illustrated in FIGS. 79A-79C. Asdescribed herein, the non-flat section of the braid 108 is tubular andhas a generally round circumference. Other possible embodiments includeflattened, oval, or other generally oblong cross-sectional shapes. Thefirst color strand 3060 is braided into the outer wall of the firstnon-flat section 3132 (FIG. 80A) and runs through the flat section 3136(FIG. 80C), and is subsequently transitioned to form a core 3064 of thesecond non-flat section 3134 (FIG. 80B). The second color strand 3062forms a core 3064 of the first non-flat section 3132 (FIG. 80A), runsthrough the flat section 3136 (FIG. 80C), and is subsequentlytransitioned to be braided into the outer wall of the second non-flatsection 3134 (FIG. 80B). In the example of FIG. 79C, the second colorstrand 3062 is white or non-distinguishing color from other 15 strands.

FIGS. 81 and 82 illustrate an example operation of the braiding assembly3002 for braiding a braid 108 with a trace strand 3060, as described inFIGS. 79-80. In particular, FIG. 81 illustrates example positions of thehorn gear assemblies 3032A-3032F and 3034A-3034B of the braidingassembly 3002 for braiding the non-flat section of the braid 108 with acore 3064. FIG. 82 illustrates example positions of the horn gearassemblies 3032A-3032F and 3034A-3034B of the braiding assembly 3002 forbraiding the flat section of the braid 108 with a trace strand 3060.

In at least some embodiments, the braiding assembly 3002 for braiding abraid 108 as illustrated in FIGS. 79-80 is operated similarly to thebraiding assembly 3002 (FIGS. 69-71) for braiding a braid 108 asillustrated in FIG. 68. As many of the concepts and features are similarto the braiding assembly 3002 of FIGS. 69-72, the description for thebraiding assembly 3002 as illustrated in FIGS. 69-72 is herebyincorporated by reference for this embodiment. Where like or similarfeatures or elements are shown, the same reference numbers will be usedwhere possible. The following description for this embodiment will belimited primarily to the differences from the braiding assembly 3002 ofFIGS. 69-71.

In this embodiment, the braiding assembly 3002 includes additionalbobbin carrier assembly 9, in addition to 16 bobbin carrier assemblies1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B, 5A, 5B, 6A, 6B, 7A, 7B, 8A, and 8B.

Referring to FIG. 81, when the braiding assembly 3002 operates to braida flat section (e.g., the flat section 3132, 3134) of the braid 108, thebobbin carrier assembly 9 is carried by the horn gear assemblies3032A-3032F and 3034A and 3034B, together with the other 16 bobbincarrier assemblies. The bobbin carrier assembly 9 is arranged such that,in the transition start position as depicted in FIG. 79A, the bobbincarrier assembly 9 is inserted in the slot 3044F of the second horn gearassemblies 3034A and 3034B. The bobbin carrier assembly 9 is guided by acore retraction mechanism 3070. In at least some embodiments, the coreretraction mechanism 3070 for the bobbin carrier assembly 9 can beconfigured similarly to the retraction mechanism 3050 as describedherein.

Referring to FIG. 82, when the braiding assembly 3002 operates to braida non-flat section (e.g., the non-flat section 3136) of the braid 108with a core 3064, the bobbin carrier assembly 9 is retracted from thehorn gear assemblies 3032A-3032F and 3034A and 3034B, as illustrated inFIG. 82. The retracted bobbin carrier assembly 9 operates as the core3064 of the non-flat section of the braid 108. In at least someembodiments, the core retraction mechanism 3070 can be used toselectively retract the bobbin carrier assembly 9.

In accordance with the principles of the present disclosure, manyalternative embodiments and arrangements of the braiding assembly 3002are possible. These alternative embodiments enable greater flexibilityfor defining different paths for the bobbin carrier assemblies andenable the braiding machine 100 to make a wider variety of differentbraid structures and configurations. Referring to FIG. 81, for example,the braiding assembly 3002 can include a track plate 3020 having anactive track 3102 and a passive track 3202. In at least someembodiments, the active track 3102 is the same as the active track 3102as illustrated in FIGS. 65 and 66. The passive track 3202 is similar toones described in FIGS. 3A-3F. For example, the passive track 3202 isformed by grooves or slots 3204 defined in the track plate 3020. Thepassive track 3202 includes a first set of passive sub-tracks 3210A and3210B, which are adjacent to the active sub-tracks 3108A and 3108B, asecond set of passive sub-tracks 3210C and 3210D, which are adjacent tothe active sub-tracks 3108C and 3108D, a third set of passive sub-tracks3210E and 3210F, which are adjacent to the active sub-tracks 3108E and3108F, and a fourth set of passive sub-tracks 3210G and 3210H, which areadjacent to the active sub-tracks 3110A and 3110B.

The passive sub-tracks 3210A-3210H correspond to passive horn gearassemblies 134A-134H, respectively, and guide the bobbin carrierassemblies 122 as they are propelled by the passive horn gear assemblies134A-134H as explained herein. Additionally, the bobbin carrierassemblies 122 can selectively move between the active track 3102 andone or more of the passive tracks 3202 as described herein. A pluralityof gates 3026 are arranged between the active and passive tracks 3102and 3202 for selective transition of the bobbin carrier assemblies 122therebetween, as described herein. With the passive sub-tracks3210A-3210H, braids with a variety of color pattern changes can beproduced as described herein.

Other embodiments are possible in the braiding assembly 3002 with thepassive track 3202. As illustrated in FIG. 83, for example,configuration of the passive track 3202 can be modified similarly toones described in FIGS. 3B-3F.

As explain herein, the braiding machine 100 in accordance with thepresent disclosure has various advantages over other braiding machines.The braiding machine 100 can use a different number of bobbin carrierassemblies with a predetermined number of horn gear assemblies. In theillustrated examples, the braiding machine 100 can use eight horn gearassemblies to carry 16 or 17 bobbin carrier assemblies. In otherembodiments, the eight horn gear assemblies of the braiding machine 100can guide different numbers of bobbin carrier assemblies. In contrast,other braiding machines are designed to use a number of bobbin carrierassemblies with the same number of horn gear assemblies. For example,the other braiding machines carries either bobbin carriers with eighthorn gear assemblies, or 16 bobbin carriers with 16 horn gearassemblies. Such other braiding machines can be designed to perform aprocess for swapping two bobbin carrier assemblies for changing shapes(e.g., non-flat and flat sections) and/or patterns of a braid. For theswapping process, the braiding machines at least two different speedprofiles for the horn gear assemblies thereof. For example, at least oneof the horn gear assemblies can have a constant speed profile and anacceleration/deceleration profile to swap two bobbin carriers. Suchdifferent speed profiles require an actuation system with a highercapacity, such as a motor with a higher capacity. Further, the changingspeed of horn gear assemblies in the acceleration/deceleration profilecauses associated bobbin carriers to be subjected to a centrifugal forcethat pulls out the bobbin carriers from the horn gear assemblies,thereby increasing a risk that the bobbin carriers are disengaged fromthe horn gear assemblies. In contrast, the braiding machine 100 of thepresent disclosure does not need a process for swapping bobbin carriersduring braiding and is configured to maintain a constant speed of thehorn gears throughout the braining process.

The braiding machine 100 of the present disclosure is capable ofbraiding a braid with at least 16 strands in a 1-over-1 configuration,using 8 horn gear assemblies. The braiding machine 100 can thus usestrands having a larger diameter to make a braid having a smallerdiameter, compared to a braid that is produced by other braidingmachines (as described above) and is not truly in a 1-over-1configuration. Thus, a braid produced by the braiding machine 100 of thepresent disclosure can have a thicker wall than other braids. Forexample, a 16-strand braid with size #2 that is braided by the otherbraiding machines can use 8 strands with 55 dtex and 8 strands with 110dtex to produce a braid diameter of about 0.024 inches. In contrast, a16-strand braid with size #2 that is braided by the braiding machine 100of the present disclosure can use 16 strands with 100 dtex to produce abraid diameter of about 0.024 inches. As such, the braiding machine 100can perform tight braiding to improve the strength of the braid.

The braiding machine 100 of the present disclosure can also produce abraid with a core and change the configuration of the core in the braid,as illustrated herein. In contrast, the other braiding machines are notconfigured to selectively change the configuration of a core in a braid.Further, the braiding machine 100 requires one track distance for fullrotation while the other braiding machines require two or more time atrack distance for full rotation.

The various examples described above are provided by way of illustrationonly and should not be construed to limit the scope of the presentdisclosure or the following claims. Those skilled in the art willreadily recognize various modifications and changes that may be madewithout following the example embodiment illustrated and describedherein, and without departing from the true spirit and scope of thepresent disclosure and claims.

What is claimed is:
 1. A surgical braid comprising: two non-flatsections; a tape section, tape section being generally flat, the tapesection having a determined number of strands extending from one of thenon-flat sections to the other non-flat section; and the tape sectionthe comprising a single braid, and the two non-flat sections and thetape section being formed with a continuous and bifurcation-less braid.2. The surgical braid of claim 1 wherein: each non-flat sectioncomprises a circumference, the circumference having a generally non-flatshape; and the non-flat shape is a generally oval shape.
 3. The surgicalbraid of claim 2 wherein each non-flat section is non-tubular.
 4. Thesurgical braid of claim 3 wherein each non-flat section is coreless. 5.The surgical braid of claim 2 wherein the tape section is non-tubular.6. The surgical braid of claim 1 further comprising: a plurality ofstrands braided together; first and second transition portions, thefirst transition portion between one non-flat section and the tapesection, the second transition portion between the other non-flatsection and the tape section; the tape section comprising first andsecond edge portions extending between the first and second transitionportions, the first edge portion oppositely disposed from the secondedge portion; and the plurality of strands being interlaced into asubstantially uniform pattern within the tape section, the substantiallyuniform pattern extending between the first and second transitionportions and between the first and second end portions.
 7. The surgicalbraid of claim 6 further comprising: first and second end portions, thefirst end portion being oppositely disposed from the second end portion;and two or more of the strands being continuously braided between thefirst and second end portions.
 8. The surgical braid of claim 7 whereinthe tape section is spineless.
 9. A surgical braid comprising: aplurality of strands comprising a first trace strand, the first tracestrand comprising a color distinguished from a color of two or moreother strands in the plurality of strands; two non-flat sections, eachnon-flat section has a generally tubular wall and defines a channel; atape section, the tape section being generally flat and being positionedbetween the two non-flat sections, the tape section comprising a singlebraid, and the two non-flat sections and the tape section being formedwith a continuous and gap-less braid; and the first trace strand isbraided into the generally tubular wall of one non-flat section, isbraided into the substantially uniform pattern of the tape section, andextends through the channel of the other non-flat section.
 10. Thesurgical braid of claim 9 wherein: the plurality of strands comprises asecond trace strand, the second trace strand comprising a colordistinguished from the color of the two or more other strands in theplurality of strands; and the second trace strand extends through thechannel of the one non-flat section, is braided into the substantiallyuniform pattern of the tape section, and is braided into the generallytubular wall of the other non-flat section.
 11. The surgical braid ofclaim 10, wherein the color of the first trace strand is different thanthe color of the second trace strand, and the colors of the tracestrands are selected from the group consisting essentially of: blue,green, violet, brown, purple, black, or white.
 12. The surgical braid ofclaim 10 wherein the plurality of strands comprises n strands, each ofthe two non-flat sections comprises n−1 strands braided into the tubularwalls, and the tape section comprises n strands braided into thesubstantially uniform pattern, wherein n is a whole number.
 13. Thesurgical braid of claim 12 wherein n equals
 17. 14. The surgical braidof claim 1 further comprising more than two non-flat sections and morethan one tape section, the non-flat sections and the tape sectionsalternating along the length of the surgical braid.
 15. A surgical braidcomprising: a plurality of strands braided into two non-flat sectionsand a tape section, the tape section being generally flat and positionedbetween the two non-flat sections; first and second end portions, thefirst end portion being oppositely disposed from the second end portion,two or more of the strands being continuously braided between the firstand second end portions; first and second transition portions, the firsttransition portion between one non-flat section and the tape section,the second transition portion between the other non-flat section and thetape section; the tape section comprising first and second edge portionsextending between the first and second transition portions, the firstedge portion oppositely disposed from the second edge portion; and theplurality of strands being interlaced into a single braid and asubstantially uniform pattern as they pass through the tape section, thesingle braid and substantially uniform pattern extending between thefirst and second transition portions and between the first and secondend portions forming a single flat braid between the two non-flatsections.
 16. The surgical braid of claim 15 wherein the plurality ofstrands comprises n strands, each of the two non-flat sections comprisesn−1 strands braided into tubular walls, and the tape section comprises nstrands braided into the substantially uniform pattern, wherein n is awhole number.
 17. The surgical braid of claim 15 wherein each non-flatsection is coreless.
 18. The surgical braid of claim 15 wherein eachnon-flat section comprises a circumference, the circumference beinggenerally out-of-round.
 19. The surgical braid of claim 15 furthercomprising more than two non-flat sections and more than one tapesection, the non-flat sections and the tape sections alternating alongthe length of the surgical braid.